SATPC0034310 Tab 04 4 SOW_Redacted.pdf

TDEA TSPD Characterization and Sub-Element Manufacturing SOW

Summary/Background Thermoplastics Development for Exploration Applications (TDEA) seeks to advance thermoplastic composite material structures technology. This includes demonstration of a relevant structural concept called the Thermoplastic Space Point Design (TSPD). The TSPD effort shall establish relevant in space weld technologies that can be applied to truss structures. TDEA needs a series of flat plates to develop and characterize ultrasonic welds with, and a set of truss joint plates and vertical truss elements to assemble using the developed ultrasonic weld method for joint characterization and verification. The TSPD joint and vertical sub-element (VSub-E) are shown in figure 1.

All parts are made from Toray TC1225/T700 slit tape material using Automated Fiber Placement. The government shall supply the 12” wide parent tape material to slit. The vendor shall slit material and manufacture all parts and inspect all parts prior to delivery.

The tooling will be designed, fabricated, and delivered by NASA. The tool design shall incorporate NIAR part spring-back results, and NIAR will review the drawings prior to tool manufacturing. A development effort shall be identified, with demonstration parts made before producing final parts. This SOW defines the materials, information NASA will supply to the vendor, and the deliverables the vendor shall supply that enables TDEA TSPD demonstrations.

Figure 1: TSPD Truss Joint, and Vsub-E test assembly

Tasks / Requirements

NASA Provided Material: NASA will provide released TSPD drawings and material for this effort. NASA provides 260 lbs of TC1225/T700 145GSM 34% RC tape material. This amount can be adjusted based on vendor provided scrap rate.

NASA Provided Tooling: NASA will provide tooling for layup and consolidation of the TSPD Truss Elements. NASA will design and fabricate the tooling. Trim tooling will not be provided. The vendor shall provide consultation and drawing reviews prior to tooling fabrication to ensure appropriate dimensions and tolerances are defined. NASA shall deliver at least 2 lay-up tools three weeks after the tool design review is complete.

Relevant Drawings: NASA will provide the following drawings to be used for this effort.

• TRUSS ELEMENTS

o TDEA-400, TSPD Joint Splice Plate o TDEA-403-02, TSPD Vertical Truss Member

• FLAT PANELS

o TDEA-331, TTPD PAEK Flat Panel (18” x 16”) o TDEA-431, TSPD Diagonal Truss, Flat Panel (18” x 24”) o TDEA-433, TSPD Horizontal Truss, Flat Panel (18” x 12”) o TDEA-435, TSPD Vertical Truss, Flat Panel (18” x 12”) o TDEA-437, TSPD Joint Splice Plate, Flat Panel (18” x 42”)

Development Planning:

The vendor shall plan and communicate development activities that ensure Splice Plate and Vertical Truss Element drawing tolerances can be achieved through process verification. A schedule shall be presented to show manufacturing development integrated with deliverable dates provided below. The plan shall be outlined in a development plan review.

Fabrication Effort.

The vendor shall slit the material provided by NASA.

The vendor shall fabricate 5 flat panels for weld trials and NDE evaluations. These weld trial panels are defined in TDEA-331, 431, 433, 435 and 437. Note each weld trial panel has intentional defects as defined in the drawings. NDE shall be performed with those defects providing a defect standard basis.

The vendor shall layup, cure, and NDE TSPD vertical truss elements, and Joint Splice Plates. Then the vendor shall cut parts to the drawing configuration and measure critical dimensions shown on the drawing, reporting anomalies. NDE shall be reported with without anomalies.

NDE Requirement NDE shall be performed by the vendor using a technique demonstrated to find flaws 0.25 inch in diameter or larger. Demonstration is based on NDE standards referenced earlier. All detectable flaws shall be reported. Flaws smaller than 0.25 inch that agglomerate shall be reported.

Deliverables

Process Planning

• Provide a process development plan including workflow and schedule. This can be a MS Word or MS PowerPoint presentation - 2 weeks after receiving order (ARO)

• TSPD Structure Element Process Development

• For identified process development steps, deliver trial data, and recommended process for element fabrication. Provide manufacturing schedule and plans for non-conformance

• Hold a Process Planning Meeting - 3 weeks ARO

Problem Reporting

• The vendor shall provide bi-weekly written status reports. This can be via email and shall included work accomplishments for that time period and plans for the next two weeks. The vendor shall report all anomalies that result in a schedule impact of greater than one week within 48 hours. The problem report shall include definition of the problem encountered, the root cause, corrective action, and schedule impact.

Flat Panels

• Deliver 5 flat panel panels. One panel each is required per the drawing. Delivery includes NDE reports.

o TDEA-437, TSPD Joint Splice Plate, Flat Panel - Mar 29, 2024 o TDEA-431, TSPD Diagonal Truss, Flat Panel - Mar 29, 2024 o TDEA-433, TSPD Horizontal Truss, Flat Panel - Apr 3, 2024 o TDEA-435, TSPD Vertical Truss, Flat Panel - Apr 3, 2024 o TDEA-331, TTPD PAEK Flat Panel - Apr 5, 2024

TSPD Element Tools

• Participate in NASA tool design review – within 5 days of contract award

• Written recommendations for TDEA-63X tool design drawings. – 2 days after NASA tool design review

TSPD Vertical Sub-Element Parts

• TSPD-400, TSPD Joint Splice Plate o Deliver 18 for sub-element test articles and NDE reports – Apr 29, 2024 o Deliver 14 for later RUC assembly and NDE reports – May 27, 2024

• TSPD-403-02: Vertical / Short Version – 18 inches long o Deliver 18 for sub-element test articles and NDE reports – Apr 29, 2024

Period of Performance

Feb 2024 to July 2024.

Travel / ODC Requirements

None.

Technical POC

Name :

Title: Chemical Engineer Phone Number: 216-372-3087