Statement of Work - FSW.pdf

Statement of Work LBNF Prototype Horn A and Test Stand Stub Stripline Welding

For the period July 1, 2024 through August 14, 2024

Statement of Work - Addendum – LBNF Prototype Horn A

Adrian Orea, FNAL

Fermi National Accelerator Laboratory 2

1. Overview

This Statement of Work (SOW) is made between a capable Friction Stir Welding (FSW) vendor and the LBNF Project at Fermi National Accelerator Laboratory (FNAL). This document constitutes an agreement between said vendor and FNAL for friction stir welding of the LBNF Horn conductor buswork, commonly referred to as the “stripline”. This document is not legally binding.

For the LBNF project at FNAL, a combined 300 kA pulse will be transmitted along a 6XXX series aluminum stripline to a toroidal focusing magnet, known as the horn. FNAL is starting fabrication of the second revision of the stripline piece parts and seeks fabrication assistance from a vendor to friction stir weld the joints per specifications defined in the drawings and welding requirements document. The overall stripline assembly is composed of 9 layers, with each layer consisting of several bent or machined blanks. All blanks are provided within exact weldment specifications with integrated weld shrinkage allowance and run-on/run-off tabs. These stripline layer weldments are notable due to the importance of their performance with respect to the overall horn system, the amount of design and serial fabrication work required for completion, and the demanding tolerance stackup originating from piece-part production through the finished weldments.

The scope of this document encompasses two phases for a vendor that has not been qualified by the LBNF team following the requirements in phase 1 of section 2 and 3 of this SOW. A previously qualified vendor may begin at phase 2 having already completed the equivalent of Phase 1 to qualify. Unqualified vendors will need to utilize their resources to weld LBNF stripline sample pieces, which reflect the weld joint geometry and material combinations of the production stripline blanks. These samples must be procured by the vendor and need to follow the notes from the drawings provided by FNAL. If qualified, the results of this phase, including tooling, fixturing, and process development, will be used to provide a 100% complete stripline assembly. All phases must adhere to FNAL document ED0010082: FNAL Friction Stir Welding Requirements for Conductor Buswork. The schedule for providing a complete stripline assembly is firmly set to adhere to the overall Horn A production schedule required by the project. Need for qualification will not extend the need by date.

2. Responsibilities

Phase 1: FSW Process Development and Sample Weldment and Qualification

• The vendor will perform process development to determine the weld parameters and requirements to produce acceptable quality welds, and design and manufacture all required fixturing, tooling, and supporting equipment for the welding process development. The fixtures used for the process development and welding the stripline samples will be designed in a way that it could be carried over, integrated, and reused in a later fixture for welding the stripline components, with proper modifications. It is the intent that the qualified weld process aspects (tooling, parameters, etc…) could be carried over directly to the real components. Included in this phase is the design, optimization and validation of the friction stir (FS) tool that is intended to be used for the stripline assembly detail parts.

• The vendor will procure and weld stripline sample pieces to produce a deliverable QTY 5 of each of the 4 material combinations that exist in the stripline assembly, as listed below.

The drawings of these stripline samples will be provided to the vendor by FNAL. Material certifications are required by the vendor for these samples.

Fermi National Accelerator Laboratory 3 o 6101-T6 to 6101-T6 o 6101-T6 to 6013-T651 o 6013-T651 to 6013-T651 o 6101-T6 to 6061-T6

Phase 2: Stripline Layer Weldments

• FNAL will provide ready-to-weld piece parts, drawings, 3D models, and any additional engineering or fabrication guidance to achieve weld requirements defined in ED0010082 that are not directly captured on weldment drawings. Any changes from this document or the requirements will be agreed on between FNAL and the vendor.

• The vendor will complete weldments of each stripline layer per detailed prints, with all weldments meeting the requirements specified in ED0010082 pertaining to weld efficiency, classification, finish, flatness, and preparation for return shipment.

• Following the delivery of the welded stripline layers to FNAL, FNAL’s Radiographic Tomography (RT) vendor will x- ray each weld to inspect and classify welds according to National Aerospace Standard (NAS) 1514 to ensure Class 1 conditions are met.

• The vendor will use the fixtures, tooling, equipment, and weld parameters that were fabricated and identified from the previous phase.

3. Deliverables – Vendor

Phase 1:

• Weld Parameter Development and Sample Welding o Determination of weld process parameters o Development of pin tool and shoulder diameter to meet specifications per

ED0010082 for weld zone o Sample part weldments from sample piece parts fabricated from drawings provided by FNAL that mimic weld joint geometry and all material combinations on stripline layers

▪ Weldments will conform to ISO 25239-5:2020 evaluation category B and NAS 1514 Class 1 specifications

• Particular attention will be given to weldments produced using the finalized weld parameters intended to be used for welding the stripline layers. At least 80% of these samples must meet Class 1.

▪ Maximum flatness of 0.020” over a 12” length (0.5 mm over a 305 mm length)

▪ Weld efficiency greater than 70% relative to the base material tensile strength

▪ Repeatable weld shrinkage within 0.005” – 0.015”

• Delivery of 5 weld samples of each material combination (see Phase 1 of section 2) to

FNAL for QA record keeping and x-ray qualification

Phase 2:

• Stripline Layer Weldments and Weld QA Documentation o Given the successful completion of Phase 1, the vendor will provide completed weldment assemblies for the prototype Horn A stripline in FNAL-built transport crate, oriented and packaged per ED0010082 to prevent damage during shipment

Fermi National Accelerator Laboratory 4

All phases:

▪ Stripline welds will meet ISO 25239-5:2020 evaluation category B and NAS 1514 Class 1 specifications in addition to the flatness and weld shrinkage conditions stated for the weld samples o Brief technical report for completed welds, including any noted discrepancies from process specifications

• Regular communication and reporting to FNAL (all phases) o Technical status and schedule updates provided via emails or virtual meetings

4. Deliverables – FNAL

Phase 1:

• Requirements and specifications document for stripline weldments, ED0010082

• Weld sample piece parts drawings

• Weldment drawings and any 3D models requested

• RT inspection reports/reader sheets of weld samples from FNAL’s RT vendor

Phase 2:

• Machined stripline layers ready for welding as specified in stripline layers weldment drawing package

• Transport crate for stripline layers with all required shims, dunnage, cribbing, or equivalent material protection features

• RT inspection reports/reader sheets of stripline layers from FNAL’s RT vendor

All phases:

• Regular reporting to the vendor o Technical status and schedule updates provided via emails or virtual meetings

5. Schedule

Below is the planned schedule for the project.

ID Task Completion Date

1 Process development, weldment, and QA of weld samples July 1, 2024

2 Completed weld samples delivery to FNAL July 15, 2024

3 X-Ray Inspection of weld samples at FNAL’s vendor July 17, 2024

4 Stripline layers piece parts delivery to vendor July 22, 2024

5 Weldment and QA of stripline layers August 5, 2024

6 Completed stripline layers delivery to FNAL August 12, 2024

7 X-Ray inspection of stripline welds at FNAL’s vendor August 14, 2024

Fermi National Accelerator Laboratory 5

6. Contacts

The primary contacts at FNAL for stripline welding technical management and engineering are:

• Adrian Orea — LBNF Horns Stripline Engineer

• Julio Ortega — LBNF Horn Test Systems Technical Manager

• Alan Kandziorski — Target Systems Department Fabrication Specialist

7. Quality Assurance

Quality assurance for this project will be ensured by meeting the aforementioned acceptance criteria:

• Weld x-ray classifications meet NAS 1514 Class 1 and ISO 25239-5:2020 evaluation category B conditions

• Maximum flatness of 0.020” over a 12” length (0.5 mm over a 305 mm length)

• Repeatable weld shrinkage within 0.005” – 0.015”

• Notes from the weldment drawings

The LBNF/DUNE Quality Assurance Plan (QAP) provides Quality Assurance requirements applicable to all Project Partners, encompassing all activities from research and development (R&D) through facility acceptance and component commissioning. Specific Project QA plans shall be developed by DUNE Project Partners with the assistance of the LBNF/DUNE Quality Manager for particular components or system quality assurance. Due to the limited scope of work of some of the Partners on the projects, they may elect to work under the LBNF/DUNE QA Plan for their scope of work.

The LBNF/DUNE QA manager may review Institutional QA plans for compliance with the LBNF/DUNE QA plan. Using a graded approach, supplements to institutions’ existing plans may be implemented for their LBNF/DUNE scope of work. The Institutions’ Project Managers are responsible for quality within their Project and report their Quality Assurance issues to the DUNE-US Project Manager and LBNF/DUNE QA Manager.