SATPC0035889 Tab 07 SOW_Redacted.pdf

Burst Testing GRX-810 Blisks Statement of Work (SOW)

The National Aeronautics and Space Administration (NASA), specifically Marshall Space Flight Center (MSFC) has a need for GRX-810 turbine blisk burst tests and balancing of the rotor per ISO 21940-11 to a balance grade of G6.3 or better. In total 9 rotors will undergo failure burst tests in a sealed container vacuum that shall be <400 millitorr and under room temperature conditions. The 9 rotors shall be individually tested and sped up to an operational speed of 100,000 RPM and the RPM at which failure occurs shall be documented to an accuracy of ±1 RPM to compare surface finishing methodologies.

The SOW is as follows:

1. Vendor shall be AS9100 Rev D, ISO9001:2015 certified.

2. Vendor shall be ISO14001:2015 certified.

3. Vendor shall be ISO45001:2018 certified.

4. Vendor shall be ITAR registered.

5. Burst testing shall be conducted in either a 42” test rig with 1.07m opening x 0.9m depth or a 54” test rig with 1.37m opening x 1.2m depth. The test rig shall provide an environment of vacuum <400 millitorr and room temperature. The test rig shall have operating range up to a minimum of 100,000 RPM.

6. Spin test rig shall be instrumented with Tachometer(s) to monitor rotor speed, Pk-pk shaft vibration apparatus to function as vibration monitor, Shaft Vibration FFT Signal Analyzer to function as a spectrum analyzer, and temperature measurement sensors to monitor test chamber temperature. Vendor shall also employ data acquisition to record time varying test data. Vendor shall supply Certification references for all instrumentation assets.

7. Marshall Space Flight Center (MSFC) shall provide in total 9 GRX-810 rotor burst test articles with varying lattice structures and surface finish methodologies. NASA MSFC will modify the rotor geometries to accommodate rotor unbalance correction and allow ample stock for spindle interface.

8. Documentation and Interfacing shall include the following.

a. Vendor shall maintain documentation for spin rotor assembly drawing.

b. Vendor shall maintain documentation for project management purposes.

c. Vendor shall maintain documentation for internal design review.

d. Vendor shall maintain documentation for verification/determination that transverse to polar ratio of moment of inertia is greater than or equal to 1.3 or less than 0.7 for GRX-810 alloy density.

e. Vendor shall maintain documentation for rotor balance considerations.

f. Vendor shall maintain documentation for both Technical Plan and Test

Documentation.

9. Rotor Modification & Interfacing shall include the following.

a. Vendor shall machine spindle socket to adequately interface with spin test rig.

b. Vendor shall machine surfaces 3, 4, and may opt to machine surface 2 per figure above to surface roughness requirements of Ra=0.8-1.6 𝜇𝜇m in order to grip these surfaces during machining operations.

c. Vendor shall grip surfaces 3 and 4, only while lathe and mill operations are underway.

d. Vendor shall be responsible for the machining of spindle socket and rotor support locations for balancing.

10. Rotor balance before the test shall include the following.

a. Rotor balancing per ISO 21940-11 to a balance grade of G6.3 or better.

b. Rotor shall be balanced on a Schenck HMS10BK with Instrumentation

Model:CAB925. Vendor shall provide calibration certificate reference for the balance machine.

c. Vendor shall shrink spindle post balance and check run out.

d. Vendor shall document all balancing considerations and mass removal parameters.

11. Testing shall include the following.

a. Vendor shall set up rig and check the drive.

b. Vendor shall install trip wire fence around the rotor prior to testing.

c. Vendor shall test each rotor to failure or 100,000 RPM whichever comes first.

d. Vendor shall stop the test upon failure indication.

e. Vendor shall record the speed at which failure occurs.

f. Vendor shall collect rotor fragments prior to proceeding to the next test. Failed specimens and fractured elements shall be collected, bagged, labeled, and returned to Marshall Space Flight Center (MSFC).

g. Vendor shall be responsible for all data reporting.

h. Vendor shall check the drive post-test.

12. Rotor Dynamic Analysis shall include the following considerations.

a. Vendor shall model the rotor assembly and drive turbine. Consolidated approximations of density distributions in lieu of actual lattice geometries are acceptable.

b. Vendor shall determine and provide estimates of the mode shapes.

c. Vendor shall determine and provide estimates of the imbalance response plots.

d. Vendor shall determine and provide estimates of the eigen frequency analysis.

e. Vendor shall provide detailed data reporting.

Shipping

1. Contractor shall ship all deliverables and return models to:

Marshall Space Flight Center Central Receiving, Bldg 4631

Huntsville, AL 35812

Deliverables

1. All raw and processed data results and final report are considered deliverables. The final report shall include the following for each rotor.

a. Rotor unbalance report

b. Plots of time varying data for each test which include speed, shaft vibration, rig temperature and vacuum data.

c. Raw time varying data for each test which include speed, shaft vibration, rig temperature and vacuum data in excel or CSV format.

d. Certificate of conformance

e. Test summary

f. Photographs of test set up

g. Final recorded burst speed (RPM)

h. Data reporting from the rotor dynamic analysis

2. Final technical report summarizing findings.

3. Failed specimens and fractured elements shall be collected, bagged, labeled, and returned to Marshall Space Flight Center (MSFC)