SATPC0036057 Tab 07 SOW_Redacted.pdf
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This document is a Statement of Work (SOW) for the development and production of burn resistant nickel-based alloy components using laser powder bed fusion (L-PBF) additive manufacturing.
The SOW outlines three key tasks: 1) parameter development and builds for NASA's burn resistant nickel-based alloys including OR-F1-M9, ORCAlloy-21, ORCAlloy-14, Alloy 754, and other ODS-based alloys, 2) mechanical testing of the developed alloy samples, and 3) providing the necessary powder materials for the developmental builds. The work will be performed over a 7-month period using an EOS M280 L-PBF machine made available for a minimum of 432 hours per month. NASA will provide the alloy powder, sample geometry, and models. The vendor is required to track powder lots, maintain build records, and return any excess powder to NASA. Deliverables include the developed components/samples, test reports, and powder certifications.
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| File | Type | Posted |
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| SATPC0036057 Tab 07 RDSS_Redacted.pdf |
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Burn Resistant Ni-Alloy Development and Components using Laser Powder Bed Fusion
Statement of Work (SOW)
July 26, 2024
The National Aeronautics and Space Administration (NASA), specifically Marshall Space Flight Center (MSFC) has a need for laser powder bed fusion (L-PBF) parameter development and component builds of novel additively manufactured (AM) NASA Nickel-based burn resistant alloys including OR-F1-M9, ORCAlloy-14, ORCAlloy-21, and Alloy 754/MA-754, and additional oxide dispersion strengthened (ODS) based alloys. With the various alloys being developed, L-PBF parameter optimization builds and validation are required according to custom parameter sets.
Task 1, Parameter Development and Builds for Burn Resistant Nickel-Alloys
1. The vendor shall provide a (secondary) EOS M280 L-PBF machine with parameters for builds using the burn resistant Ni-based alloys including OR-F1-M9 Alloy, ORCAlloy-21, ORCAlloy-14, 754, and other ODS-based custom NASA alloys.
2. The machine shall be made available for a minimum 432 hours per month. An estimated minimum run time of 60% is estimated to maintain machine capacity.
3. The total period of development shall be 7 months of machine time shall be made available and include a kickoff meeting with technical points of contact (POC).
4. Vendor shall use custom developed parameters for the ORCAlloy-21 alloy developed under prior development work with NASA MSFC and Glenn Research Center (GRC).
These parameters should result in a high density of 99.9% or greater and must be approved by NASA MSFC and GRC technical teams.
5. Additional parameter developments will be initiated for ORCAlloy-14, Alloy 754 (MA- 754), OR-F1-M9, other ODS-based custom NASA alloys.
6. Vendor shall notify NASA of any errors or issues during development builds.
7. Vendor shall notify NASA if powder is switched at any time to a different alloy during the
NASA alloy development builds.
8. Vendor shall complete powder removal after removal from the machine.
9. Powder lots shall be tracked on a best effort basis to determine multiple uses (for additional studies on recycled powder).
10. Vendor shall provide build records and any powder certifications associated for traceability of builds.
11. Development samples will include various metallography, mechanical testing, and parts including but not limited to injectors, nozzles, or other complex hardware.
12. Any excess powder shall be returned to NASA.
13. NASA shall provide ODS alloying of powder as needed. Vendor shall coordinate with
NASA POC’s to process powder.
14. NASA shall provide all sample geometry and models required for builds.
Task 2, Mechanical Testing of NASA AM Alloys
1. The vendor shall complete a minimum of fifty (50) mechanical tests on samples from the development builds in Task 1.
2. The testing shall include mechanical tensile and low/high cycle fatigue. Test conditions should be coordinated with the NASA technical POC and agreed upon conditions and requirements.
Task 3, Powder Development for Developmental Builds
1. The vendor shall provide the powder related to the development burn-resistant NASA alloys, including OR-F1-M9, ORCAlloy-21, ORCAlloy-14, Alloy 754. A minimum of 135 pounds shall be included to allow for developmental L-PBF builds as provided in Task 1.
2. The powder chemistry will be finalized by NASA and coordinated with the NASA technical POC and agreed upon requirements.
3. Vendor shall powder certifications associated for traceability of builds.
Shipping
1. Contractor shall ship all deliverables and process development samples to:
Central Receiving, Bldg 4631
Marshall Space Flight Center Huntsville, AL 35812
Deliverables
1. Components and development samples and parts built under Task 1.
2. Test Reports from samples in Task 2.
3. Powder certifications from Task 3.
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