SATPC0029404 Tab 04 SOW.pdf

MSFC STATEMENT OF WORK

EM40

RFQ EM40-SOW-001 New AM Tech Document Date: 7-20-2022 Page 1 of 7

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

STATEMENT OF WORK

EM40 – NONMETALLIC MATERIALS &

ADVANCED MANUFACTURING

DIVISION

ADDITIVE MANUFACTURING

STATEMENT OF WORK

Document Date: 7-20-2022 Page 2 of 7

1. Introduction

This work is for the additive manufacturing of various components for the Capability Maturation Task, New Additive Manufacturing (AM) Technology Project produced via laser powder bed fusion on an Additive Industries MetalFab1. The intent of this effort is to expose the NASA AM Team to emerging technologies that are not currently available in-house for firsthand use. As such, frequent communication and process insight, including demonstration, documentation, and potentially on-site witnessing of build preparation and processing is paramount to achieving project objectives.

2. RFQ Deliverables

The vendor shall supply an itemized quote including cost, lead time, and project schedule for every deliverable listed in Section 5 of this SOW. Additional information or explanation may be requested to award the work. Shipping costs for manufactured hardware (sent to Glenn Research Center Testing Lead listed in Section 3) shall also be included in the quote.

3. Technical Points of Contact

NASA Technical Lead:

Mallory James Marshall Space Flight Center Building 4707, Room 106C Huntsville, AL 35812 mallory.s.james@nasa.gov 256.961.9841

NASA Testing Lead:

Christopher Kantzos NASA Glenn Research Center ATTN: Christopher Kantzos MS 49-7 21000 Brookpark Rd.

Cleveland, OH 44017 christopher.a.kantzos@nasa.gov 216.433.8321

4. Quality Management System (QMS)

A QMS compliant to SAE AS9100, Quality Management Systems – Requirements for Aviation, Space, and Defense Organizations, or an alternate QMS approved by MSFC, shall be in place for all entities involved in the production or post-processing of AM hardware.

mailto:mallory.s.james@nasa.gov mailto:christopher.a.kantzos@nasa.gov

Document Date: 7-20-2022 Page 3 of 7

5. Deliverables

5.1. The vendor shall supply at least the following components printed in In718:

Part Name/ Number

Quantity Model/Drawing Name Notes

Challenge part 2 200506_am_experimental _buildplate_5-6-2020.stp

One shall be single laser (if possible), other shall be multi-laser*

Tensile specimens, ASTM E8/E8M

15 Print as a ∅ 0.55” x 3” right cylinder

3 vertical, room temp 3 horizontal, room temp 3 vertical, high temp 3 horizontal, high temp 3 vertical, stitched*

High Cycle Fatigue (HCF)

ASTM E466

9 Print as a ∅ 0.55” x 3”

3 vertical 3 horizontal 3 vertical, stitched*

High Cycle Fatigue (HCF)

ASTM E466

3 Print IAW S- 480_redlines.pdf

3 vertical, as-built surfaces

Low Cycle Fatigue (LCF)

ASTM

E606/E606M

12 Print as ∅ 0.675” x 2.75”

3 vertical, high strain 3 vertical, middle strain 3 vertical, low strain 3 vertical, stitched*

Promoted combustion rods

8 1/8” diameter, 6” length

Metallography bars

4 ½” cubes

Remove one per build prior to stress relief

Laser quality specimens

One per laser source

½” cubes, as-built

*Laser assignment, optimization, and stitch lines for challenge parts and mechanical specimens shall be reviewed and approved by MSFC Engineering prior to printing.

The specimen quantities listed above represent the minimum number of specimens that NASA intends to test and evaluate. If a vendor believes that more specimens are required to fully exercise/challenge the machine and multiple-laser architecture, proposals to that effect are encouraged and welcome. NASA is interested in exercising any automated laser assignment algorithms the machine may have and comparing the material quality to that of manually assigned and/or single laser specimens.

Document Date: 7-20-2022 Page 4 of 7

5.2. Pre-Processing

5.2.1. Machine Requirements

The following machine information shall be provided:

Machine Information Machine Serial Number Parameter lock process Is machine single material dedicated? If not, define changeover process.

Virgin or reuse powder and qualification of powder Recoater material, speed Build plate material and heating temperature.

Powder dosage factor (% of layer thickness) Atmosphere Information Inert Gas Used Ventilator Flow Rate Relative Humidity / Moisture Control Oxygen Error Limits Parameter Information Build Parameter File or cryptographic hash of the parameter set.

Build Report (machine output detailing any build errors/cautions, etc. – analogous examples are Concept Laser Protocol files or EOS Job Quality Reports) Output of any process monitoring capabilities, if applicable

5.2.2. STL Processing Requirements

The .stl file shall be processed by the vendor using their best practices to ensure the highest resolution feasible/reasonable for the specimens.

5.2.3. Feedstock Material Requirements

The feedstock material used does not need to be virgin powder, however feedstocks shall be controlled by industry standard or internal company specifications. [Note: For guidance regarding requirements for powder feedstock controls, see NASA-STD-6030, Table 9.] Powder feedstock certificates of conformance for lots used for hardware manufactured under this effort shall be made available upon request.

5.2.4. Labeling

Labels notating build and specimen number shall be printed on mechanical specimens at the top of the bar, not down the gauge of the bar. Location for labeling other components shall be approved by MSFC Engineering.

5.2.5. Part Orientation & Build Layout

Document Date: 7-20-2022 Page 5 of 7

Unless a build layout is provided, parts shall be oriented and arranged according to the vendors best practices and approved by MSFC engineering prior to starting the build.

5.3. Additive Build

5.3.1. Laser assignment, optimization, and stitch lines for challenge parts and mechanical specimens shall be reviewed and approved by MSFC Engineering prior to printing.

5.3.2. Documentation regarding laser scan strategy, including but not limited to laser overlap regions shall be provided for each build.

5.3.3. MSFC engineering shall be made aware of build date(s) NLT than 10 business days prior to print and at least one witness permitted to be on-site for build if desired.

5.4. Post-Processing

5.4.1. Stress Relief

After removing one metallography specimen and all laser quality specimens per each build, stress relieve remaining hardware on the build plate and remove via bandsaw or wire EDM.

5.5. Documentation

5.5.1. Material Information

The vendor shall supply the following information about all materials used:

5.5.1.1. Manufacturer

5.5.1.2. Manufacturing Date

5.5.1.3. Lot Number

5.5.1.4. Material Certification from the Supplier

5.5.1.5. Recycle Count

5.5.2. Build Layout

Documentation of the build layout shall be provided for approval by MSFC prior to printing.

5.5.3. Build Parameters

Document Date: 7-20-2022 Page 6 of 7

Parameters used in the build shall be reported including but not limited to special variations for thin walls, overhangs, and stitched regions. The machine’s standard job report is a good starting point for this deliverable. Additional insight into build parameters that may be available shall be discussed and determined in engineering support meetings.

5.5.4. Heat Treatment

Results of all heat treatments shall be provided. This includes atmospheric conditions, ramp rate, dwell time, and temperature for the entire profile of the heat treat sequence.

5.5.5. Production data

5.5.5.1. In-situ Process Monitoring

If used as a quantitative indicator of part quality for part acceptance, passive in-situ process monitoring techniques shall be identified and details provided to MSFC Engineering.

5.5.5.2. Process Restarts

Build stops and restarts are not permitted.

6. Engineering Support

The vendor shall provide engineering support for pre-processing and build planning meetings.

Plan for approximately one one-hour virtual meeting per week for the duration of the project.

RFQ EM40-SOW-001 New AM Tech Document Date: 7-20-2022 Page 7 of 7

Appendix A – Models and Drawings

200506_am_experim ental_buildplate_5-6-2

S-480_redlines.pdf