05-15-17_Nickel_Alloy_718_Powder_SOW_May_2017.pdf

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STATEMENT OF WORK Nickel Alloy 718

1. Objective/Requirements

Marshall Space Flight Center requires 3,500 kilograms of Additive Manufacturing grade Nickel Alloy 718 powder to use in Laser Powder Bed Fusion machines.

2. Characteristics, Scope, and Specs

Requirements for the Nickel Alloy 718 powder are in the attached specification entitled

“Powder Specification: Inconel 718 for Laser Powder Bed Fusion Additive

Manufacturing”

3. Place of Performance

Marshall Space Flight Center in Huntsville, AL

4. Period of Performance

Delivery shall occur within 90 days of contract award.

CHECK THE MASTER LIST—

VERIFY THAT THIS IS THE CORRECT VERSION BEFORE USE

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EM42 DOCUMENT - 0078

National Aeronautics and REVISION: PROCUREMENT RELEASE

Space Administration EFFECTIVE DATE: MAY 9, 2017

George C. Marshall Space Flight Center Marshall Space Flight Center, Alabama 35812

Powder Specification:

Inconel 718 for Laser Powder Bed Fusion

Additive Manufacturing

PROCUREMENT RELEASE – MAY 2017

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DOCUMENT HISTORY LOG

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TABLE OF CONTENTS

1. SCOPE 6

1.1 Introduction ---------------------------------------------------------------------------------------- 6

1.2 Applicability --------------------------------------------------------------------------------------- 6

2. APPLICABLE DOCUMENTS 6

2.1 General ---------------------------------------------------------------------------------------------- 6

2.2 Non-Government Documents ------------------------------------------------------------------- 6

3. ACRONYMS AND DEFINITIONS 7

3.1 Acronyms ------------------------------------------------------------------------------------------- 7

4. ADDITIVE MANUFACTURING POWDER REQUIREMENTS 7

4.1 Powder Acquisition ------------------------------------------------------------------------------- 7

4.1.1 Vendor Quality Management 7

4.1.2 Method of Manufacture 7

4.1.3 Powder Lots 7

4.1.4 Feedstock 8

4.1.5 Powder Composition 8

4.1.5.1 Composition 8

4.1.5.2 Chemical Check Analysis 8

4.1.6 Particle Shape and Size Distribution 8

4.1.6.1 Size Distribution 9

4.1.6.2 Measurement and Reporting of Particle Size Distribution 9

4.1.6.3 Powder Shape and Morphology 9

4.1.6.4 Powder Lot Additions 9

4.1.7 Powder Sample Collection 9

4.1.8 Handling and Packaging 9

4.1.9 Powder Certificate of Conformance 9

4.2 Independent Receiving Inspection ------------------------------------------------------------- 10

4.2.1 Chemical Composition 10

4.2.2 Powder Morphology and PSD 10

5. DATA DELIVERA BLES 11

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LIST OF TABLES

Table 1. IN718 Powder Composition

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1. SCOPE

1.1 Introduction

This specification establishes the process controls and engineering requirements for the powder used during Powder Bed Fusion (PBF) Additive Manufacturing (AM) of alloy N07718, trade name Inconel 718. Herein, the powder alloy shall be referred to as IN718-AM. In order to ensure a consistent metallurgical process, this specification identifies requirements for control of the procurement, inspection, and subsequent handling and use of AM powder. Specifically, controls are levied for key aspects of the powder production process, the powder chemistry and particle size and shape distribution, inspection requirements, contamination control, storage and handling, and powder reuse limitations in the AM process.

1.2 Applicability

The current revision of this AM powder control specification is not applicable to the production of flight-quality AM hardware.

This specification is applicable to the scope of National Aeronautics and Space Administration

(NASA) Marshall Space Flight Center (MSFC) AM operations, including, but not limited to, the following: general AM process development, AM material characterization, production of AM build demonstration hardware, production of non-flight test and development hardware.

2. APPLICABLE DOCUMENTS

2.1 General

Documents listed in this section are referenced within this standard. Governing NASA standards are expected to have been levied at the project or program level. The effective date issue of those documents not specifically identified by revision identifier shall be the latest issue in effect.

2.2 Non-Government Documents

ASTM B215 Standard Practices for Sapling Metal Powders

ASTM E1019 Standard Test Methods for Determination of Carbon, Sulfur, Nitrogen, and Oxygen in Steel, Iron, Nickel, and Cobalt Alloys by Various

Combustion and Fusion Techniques

ASTM E354 Standard Test Methods for Chemical Analysis of High-Temperature, Electrical, Magnetic, and Other Similar Iron, Nickel, and Cobalt Alloys

ASTM B214 Standard Test Method for Sieve Analysis of Metal Powders

SAE AS9100 Quality Management Systems – Requirements for Aviation, Space, and

Defense Organizations

SAE AMS 2269 Chemical Check Analysis Limits, Nickel, Nickel Alloys, and Cobalt

Alloys

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3. ACRONYMS AND DEFINITIONS

3.1 Acronyms

AM Additive Manufacturing

ASTM American Society for Testing and Materials

CoC Certificate of Conformance

OWI Operational Work Instruction

PBF Powder Bed Fusion

PPM Parts Per Million

PSD Particle Size Distribution

QMS Quality Management System

SAE Society of Automotive Engineers

4. ADDITIVE MANUFACTURING POWDER REQUIREMENTS

This section provides requirements that are necessary to ensure control of the powder feedstock used in PBF AM and its use during processing. This control is needed to ensure consistent performance of the metallurgical process. Requirements have been defined for chemistry, particle size and shape, contamination control, reuse, and storage and handling.

4.1 Powder Acquisition

This section specifies requirements to be levied for the procurement of IN718-AM powder.

4.1.1 Vendor Quality Management

Powder producers and suppliers shall operate under a Quality Management System (QMS) compatible with standard aerospace quality expectations, such as SAE AS9100 or other system demonstrated equivalent. The active QMS governing powder production and subsequent processing will be identified and certified as active and applicable by the powder producer and supplier, if they are not the same.

4.1.2 Method of Manufacture

The IN718-AM powder shall be produced using vacuum or inert induction melting and gas atomization in argon. The furnace charge for atomization will consist of master alloys, virgin melt stock, solid revert of controlled purity, or any combination thereof.

4.1.3 Powder Lots

Unless explicitly specified by the purchase request, the requested quantity of powder shall be supplied as a single lot. The single lot may be supplied as a blend of multiple heat lots.

Blending of multiple heat lots into a single lot is allowed only if every lot blended is verified independently to meet all aspects of this specification. Heat lot numbers and their independent

J-1-8 certification will be provided for each blended lot. Blending of heat lots will not be used to control chemistry or particle size distribution. Blending of heat lots will not occur other than at the original powder producer.

4.1.4 Feedstock

Any and all heats of material used to make a blend must meet the chemistry listed in the applicable powder specification. The lot powder chemistry shall not be made by blending powder heats of material with any elements out of their specified range.

4.1.5 Powder Composition

4.1.5.1 Composition

The IN718-AM powder shall have composition as shown in Table 1. Oxygen and nitrogen shall be limited to 300 parts per million (PPM) for each.

Table 1. IN718-AM Powder Composition

Composition (weight %)

Element Minimum Maximum

Ni 50.00 55.00

Cr 17.00 21.00

Nb 4.75 5.50

Mo 2.80 3.30

Ti 0.65 1.15

Al 0.20 0.80

Co — 1.00

Cu — 0.30

C — 0.08

Si — 0.35

Mn — 0.35

P — 0.015

S — 0.015

B — 0.006

N -- 0.03

Fe Remainder

4.1.5.2 Chemical Check Analysis

Chemical check analysis limits of Society of Automotive Engineers (SAE) AMS 2269 are applicable, but shall not be used to alter the range of composition limits specified in Table 1.

4.1.6 Particle Shape and Size Distribution

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4.1.6.1 Size Distribution

The IN718-AM powder particle size distribution (PSD) shall target a particle size range of 10 m to 45 m. Particles greater than 45m in size shall be limited to ≤ 1.0% by weight through sieving at 325 mesh. If necessary, the powder lot can be further processed such that the volume percent of particles smaller than 10 m is ≤ 3%.

4.1.6.2 Measurement and Reporting of Particle Size Distribution

Each powder lot shall be supplied with PSD verification to include, at minimum, volume percent

+325 mesh by sieve analysis per American Society for Testing and Materials (ASTM) B214, and volume percent below 10m as measured with laser diffraction or direct image analysis methods.

Method of PSD measurement shall be specified. Other methods may be used if agreed upon prior to contract award.

4.1.6.3 Powder Shape and Morphology

IN718-AM powder shall be primarily spherical in shape, free of significant satellite particles, and have smooth surfaces. Powder vendor may meet these requirements by supplying images of a mono-layer sample of the powder lot of approximately 0.5 cm2 area at sufficient magnification/resolution to observe particle shape and confirm the absence of significant satellite particles.

4.1.6.4 Powder Lot Additions

Post-production additions to the powder lot for control of PSD or chemistry are not allowed.

4.1.7 Powder Sample Collection

Sampling required to determine PSD and composition must meet minimum acceptable methods of powder sampling as defined in ASTM B215.

4.1.8 Handling and Packaging

The IN718-AM powder must be handled and processed under inert atmosphere as vendor’s process allows. All exposures to atmosphere during handling and processing will be described prior to processing, and allowed with pre-approval by NASA. IN718-AM powder shall be packaged in air-tight, inert gas filled containers or drums no larger than 20 kg each.

4.1.9 Powder Certificate of Conformance

The IN718-AM powder shall be delivered with Certificates of Conformance (CoC) specifying lot number, and the date and facility location of powder production, and verification of compliance to all requirements of Section 4.1. If the provided lot of powder is a blend of heat lots, the CoC must contain compliance information for each blended lot.

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4.2 Independent Receiving Inspection

Upon delivery, each IN718-AM powder lot shall undergo independent sampling inspections to verify the following. Results of the independent evaluation shall be added to the vendor CoC and stored as a quality record.

4.2.1 Chemical Composition

Chemical composition shall be verified for carbon, sulfur, nitrogen, and oxygen per ASTM

E1019. Other elements of Table 1 shall be verified by wet chemical methods per ASTM E354 or inductively coupled plasma spectroscopy per ASTM E2594.

4.2.2 Powder Morphology and PSD

Particle shape metrics and PSD shall be determined through image analysis techniques per industry standard powdered-metal characterization (ISO, ASTM, and ANSI).

5. DATA DELIVERABLES

The Contractor shall report and document this work and fulfill the requirements of associated

Data Requirements Description (DRD) as outlined in Data Procurement Document (DPD) 1616

(Attachment J-2). The contractor shall determine the data restriction that applies to each data deliverable and mark or transmit the data restriction in accordance with section 2.3.3 of the Data

Procurement Document.

The contractor shall provide technical information concerning any invention, discovery, improvement, or innovation made by the contractor in the performance of work under this contract. Technology Reports shall be prepared in accordance with DRD 1616CD-001.

The contractor shall prepare and submit the Environmental Compliance Reports that complies with Executive Order 13693 in accordance with DRD 1616EE-001.

The contractor shall prepare and submit a Final Scientific and Technical Report that complies with the requirements of NFS 1852.235-73 in accordance with DRD 1616MA-001.

The contractor shall prepare and submit a Monthly Progress Report in accordance with DRD

1616MA-002.

The contractor shall report mishaps and safety statistics to the MSFC Industrial Safety Branch in accordance with DRD 1616SA-001. The contractor shall submit directly into the NASA Mishap

Information System (NMIS) or shall use the forms listed in section 15.4 of DRD 1616SA-002 or electronic equivalent to report mishaps and related information required to produce the safety metrics.