SATPC0032595 Tab 04 SOW UPDATED.pdf

Title: Explosive Hydroforming Subscale Manufacturing Demonstration of Al-Li Alloy 2050 Friction Stir Welded Blank

Introduction:

Commercial space companies currently deal manufacturing bottlenecks for advanced forming of large and complex space vehicle structures since the number of capable suppliers is very small. As a result, the lead times for specialty formed metallic hardware is frequently the schedule driver for the entire program. Development of new technologies, such as explosive hydroforming, has potential to reduce the cost and lead time of large and complex-formed space vehicle components. Research and development of these manufacturing technologies can accelerate development of a robust lunar economy.

The current state of explosive hydroforming is Technology Readiness Level (TRL) 4 for propellant tanks and TRL 3 for launch vehicle tanks, crew vehicles, and habitats, which represent the targeted applications for commercial space. Explosive hydroforming offers potential advantages to reduce cost, mass, and lead time for large metallic bulkheads, domes, and cones to accelerate deployment of new lunar assets for NASA and the commercial space sector. A subscale ( ~2 meter) manufacturing demonstration is warranted to explore the technology, characterize the resultant performance, and advanced the TRL for future larger-scale (>5 meter) commercial manufacturing

Researchers at Lockheed Martin Space Company and NASA Langley Research Center (LaRC) have been awarded an Agency Collaborative Opportunity (ACO) proposal. The research proposal seeks to perform a manufacturing demonstration of a dome shaped part using explosive hydroforming. The demonstration article will be fabricated from a ~2-meter friction stir welded blank of aluminum-lithium alloy 2050 – an alloy of high interest for aerospace applications.

Description of Work:

As part of the ACO, NASA is required to complete a best-effort basis subscale manufacturing demonstration using explosive hydroforming to advance the TRL for future missions. Under the ACO, Lockheed Martin has agreed to supply a ~2-meter forming blank of friction stir welded 1.5-inch thick aluminum-lithium alloy 2050. The disc may need machining, trimming, or other surface preparation to facilitate explosive hydroforming. Lockheed Martin will lead the effort utilizing explosive hydroforming techniques in the forming of the aforementioned blank. The blank must be packaged and shipped using commercial best practices. Lockheed shall oversee contractual duties with any subcontractor, should the need arise, and coordinate return shipment of cut sections from the demonstration article to NASA LaRC.

The Contractor shall:

• Provide the resources necessary and/or provide management and oversight of a subcontract with a vendor for high-energy (explosive) hydroforming of aluminum-lithium (Al-Li) alloy 2050 friction stir welded blank

• Supply Al-Li 2050-T34 friction stir welded blank per Aerospace Metals Specification (AMS) 4372 and provide material certifications to ensure conformance

• Ensure any necessary preparations (e.g., surface preparation of the friction stir welded blank; machining of the blank; tooling modifications; etc.) are performed and/or discussed with any subcontractor to ensure appropriate preparations are made prior to forming

• Work with vendor to simulate the process and provide predicted deformed geometry and strain estimates associated with hydroforming

• Oversee technical work for best-effort basis hydroforming of Al-Li alloy 2050 friction stir welded blank into a dome shape utilizing existing tooling

• Work with vendor to characterize dome with light scanning technique to document the geometry of the dome

• Ensure artificial aging heat treatment of dome to yield near peak-aged mechanical properties representative of typical service property requirements

• Work with NASA and manage efforts for the cut plan for sectioning of the dome after hydroforming. Each piece shall be labeled and numbered to reference location from the original formed part.

• Coordinate shipping of cut sections to NASA Langley

• Ensure all requested deliverables are provided

• Participate in meetings with NASA Langley as needed (at least monthly) throughout the duration of the contract and include any necessary subcontractors as necessary.

Deliverables

• Supply friction stir welded Al-Li alloy 2050 forming blank

• Provide material certification for Al-Li 2050 blank material

• Develop dome cut plan, in collaboration with NASA, for sectioning after forming

• Relevant images/videos of the process/forming trial for the Al-Li 2050 friction stir welded dome, including images of the forming blank prior to forming and of the final formed part

• Light scanning documentation of final geometry

• Computational simulation prediction of final geometry and strains due to hydroforming

• Written report (PowerPoint slides and/or document in Word or PDF format) that describes the process used, processing and heat treatment parameters for this forming trial, assessment (qualitative or semi-quantitative) of the forming trial success, lessons learned/recommendations for future improvement. NASA requests delivery of documentation no later than 14 months after date of contract award.

• Cut sections as specified in cut plan from formed dome after heat treatment, then shipped to NASA Langley. NASA requests delivery of the cut sections by September 2024.

• Data Rights: NASA seeks limited data rights in all intellectual property resulting from this contract award.

Send deliverables to:

Wesley Tayon Mail Stop 188A NASA Langley Research Center Hampton, VA 23681

Award Type: NASA seeks to award a single Firm Fixed-Price Contract.

Period of Performance (PoP): NASA requests a PoP for data deliverables no longer than 14 months after data of TO Award. NASA requests a PoP for completed dome no later than September 2024.

mailto:Wesley.a.tayon@nasa.gov