RXNS_4D CT SOW OPSEC Reviewed 2024 01 11.pdf

Statement of Work for 2D/3D/Time Dependent Computed Tomography System

28 September 2023

AFRL/RXNSE

2179 12th Street

Wright-Patterson AFB, OH 45433-7718

I. Background: The requirements for a multi-purpose radiography suite are described below. The system SHOULD be a fully functional, stand-alone system to be installed in an existing shielded vault within AFRL/RXNS, Bldg. 652.

Scope: The radiography suite will be used for still and real-time (video) high resolution 2D radiography and 3D computed tomography of a variety of components including electronic assemblies and components, avionics, structural materials and components made with various manufacturing methods including additive manufacturing. The suite shall also be used for 4D (time-dependent) reconstruction of dynamic systems to include materials and structures under dynamic load and servo-mechanical or electrical systems dynamically energized.

II. Basic Requirements: The vendor provided system/ machine should provide the following:

a. Still and real-time 2D imaging using a digital detector array

b. Automated computed tomography (3D and Time Dependent (4D) reconstructions) using digital detector array

c. Capability to perform imaging using both mini (450 kV) and micro (225 kV) focal spot tubes

d. Capability to combine image data from adjacent 2D and 3D data sets to build high resolution reconstructions for large components (i.e. data mosaic)

e. Capability to perform sub-pixel image acquisition and reconstruction to improve spatial resolution.

f. Capability to perform helical scans

g. Scatter reduction for computed tomography through scatter control hardware and/ or software

h. Rotating stage with 2 axes of translation (X and Z) and tilt

i. Computer workstation control of scanning and data acquisition

j. Separate work-station for post-processing/ reconstruction

k. Digital data storage capability for all imaging modes (all file formats and sufficient storage space), except for 2D radiographs using customer supplied imaging plates.

l. Capability for transferring digital data from and to the controlling computer for analysis, display and hard copy generation.

m. Ability to create and store user defined scan plans.

n. Active remote control of all axes.

o. Installation including transportation to installation location

p. Integration of system safety interlocks into existing vault interlocks.

q. Camera based monitoring system

r. Training

III. Facility Limitations for Delivery/Installation:

a. Max weight capacity of floor:

i. Corridors = 125psf

ii. Lab = 150psf NOTE: These values come from the as built blueprints of the building and are described as live loads in the documents. More definitive weight requirements are provided in the section below. See note below in Section IV-a-ii

iii. Dead Load on Floor Slab: 3500 psi Note: This load value should not come into play but is provided for knowledge

b. Clearance limits for hallways/doorways:

i. See Figure 1 for path from delivery location to laboratory location

ii. Max height = 84” (Doorway between loading dock and hallway)

iii. Max width = 58” (Doorway to lab)

NOTE: Two entry doors are available depending on final location of system components: 1) Sliding door to vault for manipulator and possibly generators and 2) double swinging door (1 full and 1 half width) for desk and other components

IV. Detailed System Requirements:

a. System Parameters:

i. Max System Dimensions (Assembled): 6’ (width) x 8’ (height) x 12’ (length).

This includes all detectors, x-ray tube, mounting frame, manipulating stage, pumps, generator(s), and any required space for access. (see Figure 2)

ii. Maximum weight, including manipulator, x-ray tubeheads and detectors: 6000 lbs.

NOTE: The weight and footprint for calculation of live loading is for manipulator system alone, including tubeheads and detectors. If generators must be located directly next to the manipulator system, they need to be included in this weight, but the footprint will need to be adjusted accordingly as well. If the generators can be moved sufficiently far away (2 feet minimum) then they do not need to be included in the weight/ footprint.

NOTE: To meet the weight capacity value in Section III-a divide the total weight of manipulator by the overall footprint of the system.

For a system weighting 4000 lbs and having a 5’ by 8’ footprint the area load would be 100 psf (4000 lb/40 sq ft). A system with a 40 sq ft footprint can have a maximum weight of 6000 lbs.

iii. System manipulator (motion axes) should be shipped in as complete assembly as possible, but this is at the vendors discretion. Maximum weight of any single shipping crate/ container: 3500 lbs. Multiple shipping cases may be necessary to keep weight to below value above. Complete system should be shipped in as few containers as possible.

b. Stage Requirements

i. Stage Weight Capacity: 350 lbs minimum.

ii. Part Dimensional Capacity:

1. Height: 48 inches minimum

2. Diameter: 30 inches minimum

iii. Manipulation of inspection components:

1. (Z-axis) Translation between detector and X-ray tube: Minimum of 47 inches measured from center of stage to X-ray tube focal spot

2. Automated rotation at user selected translation position for CT imaging

3. Scan Travel Dimensions: (See Figure 3 for Coordinate system axis)

a. Part Stage Rotation: 360 degrees continuous

i. Stage Resolution: 0.0025 degree maximum

b. Part Stage Tilt +/- 20 Degree

c. Part Stage X motion: 30” minimum

d. Part Stage Z motion: 45” minimum

e. Detector X Motion: 20” minimum

f. Detector Y Motion: 45” minimum

g. Detector Z Motion: 45” minimum

h. Tubehead Y motion: 45” minimum

i. Detector and Tubehead motion should be capable of being decoupled, i.e the detector should be able to move independently to the tubehead

c. X-ray Tube Requirements

i. Dual Tube Configuration

1. Microfocus Tube

a. Adjustable Energy Level: 25kV – 225 kV minimum

b. Adjustable Current Range: 0 mA – 3 mA minimum

c. Power Level: 300 W minimum

d. Focal spot size: <6 microns (achievable based on tube current)

2. Minifocus Tube

a. Adjustable Energy Level: 10kV – 450kV (maximum)

b. Adjustable current level: 0 mA – 4.0 mA minimum

c. Power Level: 1400 W minimum

d. Focal spot size: 0.4 mm and 1.0mm per EN 12534

e. Powered Shutter

3. System should be capable of automatic tube switching

d. Digital Detector Array Requirements:

i. Flat Panel Detector

ii. Resolution: 16 bit minimum

iii. Minimum Active Area: 17” x 17”

iv. Max Pixel Pitch: 150 µm x 150 µm

v. Frame Rate: Adjustable with 15 FPS (minimum) using all available pixels, 25

FPS (minimum) with 2x2 pixel binning maximum

vi. Gadox Based Scintillator

vii. The position of the detector relative to the X-ray tube shall be adjustable from

12 to 44 inches (minimum) from the tubehead and shall be under computer control.

viii. Provision allowing one person to easily remove and/or shield the detector to allow use of alternate detectors (i.e. computed radiography imaging plates)

e. Computer and Controls

i. The computers shall provide sufficient speed and performance to control of all system functions to meet all listed performance requirements. All computers should be Windows based with the most up to date version of the operating system

1. The acquisition computer shall have a minimum of:

a. 8 core processor

b. 32 GB RAM

c. 1TB SSD operating drive

d. 3 TB storage drive.

e. DVD +/- RW Drive

f. 10/100/1000 Network Interface

2. The reconstruction computer shall have a minimum of:

a. 10 core processor

b. 256 GB RAM

c. 1TB SSD operating drive

d. 24 TB storage drive with RAID5 capability

e. DVD +/- RW Drive

f. 10/100/1000 Network Interface

g. Display and reconstruction processing should provide the minimum time possible based on computers offered by vendor i.e. highest performance graphics processing available. Ideally minimum of 2 GPU’s but more would be preferred

ii. Two color monitors (minimum of 1 per computer) shall be provided, each with a minimum screen size of 30-inch diagonal with 4K resolution or greater.

iii. Each computer shall have a minimum of two USB-3.0 ports available for data transfer, etc. after all peripherals are attached. In addition, multiple 10/100/1000 ports can be included in addition to the USB 3.0 to provide data transfer to external storage solutions.

iv. The operator interface shall be at the workstation with commands entered at the keyboard and mouse. Manual control of all motorized axes shall be provided utilizing current push-button controls, joystick or pendant. Axes positions shall be displayed on the monitor.

v. All peripherals (mouse and keyboard) must be wired

f. Software Requirements:

i. 2D Imaging Software

1. Non-proprietary image storage format, DICONDE Compliant

2. X-ray tube control and monitoring

3. Live image, integration and frame averaging, real-time contrast enhancement

4. Sharpening filter, smoothing filter, edge enhancement, Wallis, user definable filters

5. Histogram analysis, colorization and thresholding for density isolation

6. Image archival in at least TIF, BMP, and JPEG formats

7. Text annotation, fixed and real-time overlay (text, arrows, shapes, etc.)

8. Video file creation

9. Profile analysis function

10. Image spatial calibration and measurement in the x-y plane (interactive)

11. Ability to acquire multiple 2D image results and combine into a single result

ii. 3D Reconstruction Software

1. Recording of projections

2. Both stepped and continuous CT scan creation

3. Detector correction (offset, gain, and missing pixels)

4. Image processing tools and projection filtering

5. Slicing (cropping) at multiple angles/planes(not just the x, y, z planes)

6. Histogram analysis, colorization and thresholding for density isolation

7. Filtering (Minimum): Average, sharpen, edge enhancement, Wallis

8. X-ray tube control and monitoring

9. High speed reconstruction of volumes or freely defined partial volumes

10. AVI file generation

11. Simultaneous acquisition and reconstruction of data

12. Capture of 2D images from any selected CT slice and output to at least

TIF, BMP, and JPEG. Output of full volumetric TIF stacks.

13. Dimensional measurement tools

14. Local reconstruction capability

15. Metric measurement tools per ASTM E2737 to include CNR, SNR, and

MTF (using E2002 unsharpness gauge)

16. Ability to perform helical scans to reduce parallax

17. Ability to acquire multiple CT results and combine/ stitch into a single result

18. Capability to achieve effective 75µm x 75µm detector resolution through detector fractional pixel shift

19. Ring Reduction and Scatter Reduction algorithms

20. Creation and export of 3D surfaces as CAD model files

21. Ability to create standalone executable files for manipulation on other workstations

iii. Time Dependent (4D) and Motion CT Reconstruction

1. Provide all functionality required of 3D reconstruction

2. Provide capability to generate 3D reconstructions at successive time-frames and merge these reconstructions into dynamic reconstructions to enable analysis of state of change.

iv. Simulation Software

1. Windows based software that simulates the operation of the CT system which should include the following items:

a. Technique Development

b. Motion Programming

c. Imaging Simulation

d. System Training V. Vacuum Pump Requirements:

a. Roughing and turbo pumps shall be provided and integrated to support X-ray tube operation

b. All vacuum pumps shall be installed within the shielded vault.

VI. Generator Requirements

a. An X-ray tube generator shall be provided to supply conditioned power to all tubes as required to meet the tube specifications

b. Sufficient cabling (10 meter min) shall be provided to interface the generator to the tube head

c. Generators may be installed within the shielded vault.

VII. Miscellaneous Requirements:

a. Microfocus Copper Filter Kit

b. Minifocus Copper Filter Kit

c. Tool Kits for system

d. 18” Turntable addition

VIII. Safety Requirements:

a. The system shall be integrated into the existing vault interlock system. The interlock includes internal and cut-off switch, warning lights and two door interlock switches. A wiring diagram can be provided upon request.

b. The safety requirements and safety steps for the system must meet the requirements of T.O 33B-1-1: Technical Manual: Nondestructive Inspection Methods, Basic Theory listed below.

“Interlock System. The visible and audible warning beacons/signals SHALL be tied to an interlock system. The interlock system SHALL be placed on each door to interrupt power to the control box/tube head, stopping the irradiation process, when unauthorized access is attempted.

A time delay/interlock MAY be locally fabricated or purchased in order to meet this requirement.” “Warning Beacons. Rotating or flashing strobe-type visible warning beacons SHALL be used at all entrances to the enclosure.”

IX. Training:

The contractor SHALL provide on-site training for a minimum of five (5) days for a minimum of six (6) operators. Training SHALL cover advanced DR and 3D/4D CT methods, theory of operation, equipment operation, software operation, and system maintenance. The contractor shall provide necessary training documentation to include two (2) complete hardcopies and one (1) electronic copy of operation and system maintenance manuals. Training SHALL commence no later than two weeks following installation, or as agreed to by the contractor and the using activity. Problems will be resolved by mutual agreement of the contractor and the Contracting Officer.

X. Installation

The installation SHALL include shipping, delivery, and installation of all hardware within the laboratory at AFRL/RXNSE. Calibration and checkout SHALL be performed, with the user as a witness, to demonstrate compliance to this specification.

a. No later than sixty (60) days prior to delivery, the contractor SHALL provide a facility plan that describes in detail the necessary utilities and the installation requirements necessary to set up this equipment to be operational as intended.

This plan SHALL be submitted to AFRL/RXNSE to allow for customer site preparation prior to installation.

b. The site will be ready for installation within sixty (60) days after receipt of the facility plan.

c. Installation and testing SHALL be accomplished at a time agreeable to both the contractor and customer but no later than fourteen (14) days after delivery of the equipment. If installation and testing will not be possible within 14 days of delivery, AFRL/RXNSE will notify the contractor and a mutual agreement will be reached between the parties as to action to be taken.

d. Acceptance/Testing: Final inspection and acceptance will be made by AFRL/RXNSE personnel after the equipment is installed, is operational and has been verified, through test and demonstration, that it meets the requirements of this specification.

XI. Warranty

The contractor SHALL provide a standard warranty to include 1 periodic maintenance visit and 1 emergency repair visit within the one year warranty period with software updates to both 2D and 3D software included. The warranty must also include cost for travel, labor and parts if component replacement is required.

XII. Security Requirements

a. Operations Security (OPSEC): The contractor shall participate in all activities associated with the disciplines of the organizations Industrial Security, Information Security, Personnel Security, Operations Security (OPSEC), and Antiterrorism program, following appropriate measures in each program as required for this particular contract. Security measures are required to reduce program vulnerability from successful adversary collection, exploitation of critical information, and violations of export control requirements. The prime contractor shall ensure all subcontractors, if applicable, conform to these requirements as required by the prime contractor.

b. Program Protection Plan (PPP) Requirements: Any potential critical program information (CPI) generated as part of this effort will be reviewed to determine the need for a PPP or to be included as part of an existing PPP.

XIII. Options:

If possible the contractor shall provide the following options:

1) One (1) additional year of warranty and maintenance support to include one (1) additional periodic maintenance visit and one (1) emergency repair visit.

2) Support frame on detector capable of holding Computed Radiography (CR)

Imaging Plates (IP) with a maximum size of 14” x 17” in both hard and soft cassettes. Dimensional information can be provided if the vendor wants to provide this option

3) Integration of a linear detector and association software. This detector shall be permanently mounted adjacent to the flat-panel detector required in the base system and have the following specifications

a. Pixel Pitch: 500 micron maximum

b. 24 inch length minimum

c. 16 bit resolution

d. Automatic detector switching

e. Collimator

4) Micro positioner stage

a. 2 axis of travel with 10 µm minimum step size

b. 100 mm min travel each

c. 20 lb capacity minimum

5) Filter Wheel

a. Motorized and computer controlled from software

b. Pre-filled filter sections and blank sections for user defined options

Figure 1. Delivery Path with Dimensions

Figure 2. Location and footprint of multi-purpose radiography system

Figure 3. Coordinate system for axis movement.

Footprint for multi-purpose radiography system 6 ft

12 ft

5 ft

5 ft 4 in

1 ft

5 ft

5 ft

2 interlocked doors

Serpentine cable passage (5”x7” min opening*)

*shared with two other x-ray tubes and electrical runs

38 in