SATPC0036386 Tab 04 4 SOW.pdf

Statement of Work

Preliminary design work for unique modifications to Laserline laser welding optics and delivery fiber to support operation in a thermal vacuum environment

The government (NASA/MSFC-EM31) requires a capability to operate a high-power laser welding system, especially focusing optics and delivery fiber, mounted on a robotic arm within a thermal vacuum environment – down to 10-4

Pa and over a temperature range of 40 to 400 K. Prior to purchasing a ruggedized system laser welding system more suitable to these requirements than that is available COTS, there must be preliminary design to ensure that any ruggedized laser welding system – specifically the laser focusing optics and delivery fiber – has the most at-risk and incompatible components identified with mitigation strategies indicated. MSFC has already acquired a Laserline LDM laser system suitable for mounting upon a robotic arm so this system will serve as a baseline to expand the vacuum and temperature ranges achievable. As such, work to prepare the Laserline OTS-5 laser optics and proprietary laser delivery fiber (part of the Laserline LDM system) to support an expanded operating range in both vacuum level and temperature is required. Recognizing the difficulty of this task, all preliminary design work and technical support may be in a best-effort manner.

Some exemplar design efforts may include tes�ng the limits of exis�ng hardware components (in Laserline facili�es), crea�ng a means to control the environment that directly contacts those components, and by applying new materials. Other efforts may include ensuring the thermal expansion mismatch between the op�cs and their housing does not exceed tolerable limits by selec�ng alterna�ve materials or providing ac�ve cooling/hea�ng, adding insula�on where appropriate and not deleterious to vacuum compa�bility, and exploring ac�ve hea�ng/cooling for the op�cal fiber to avoid excessive embritlement at low temperature and coa�ng loss at high temperatures. Vacuum compa�bility will require removing any materials prone to outgassing or otherwise unstable in vacuum environments – par�cularly the op�cal fiber coa�ng and adhesive or po�ng epoxies – and cavi�es that could entrap air.

Adop�ng the previous best-effort manner and acknowledging that this is preliminary design work only for the Laserline OTS-5 laser op�cs and delivery fiber, the following deliverables are desired:

1. Laserline proprietary delivery fiber

a. Ini�al tes�ng of thermal shock resistance, approximate range of 270 to 350 K

b. Extrapola�ng temperature trends to determine performance limits without water cooling

c. Tes�ng of a fiber to determine offgassing rate in vacuum

2. Laserline OTS-5 laser op�cs

a. Simulate the thermomechanical response of the op�cs via FEM over the temperature range of 40 to 400 K

b. Iden�fying materials suitable for replacement seals that are more resilient to temperature

c. Ini�al tes�ng of thermal shock resistance, approximate range of 240 to 400 K

d. Ini�al tes�ng of low-temperature resilience, approximate range of 120 to 170 K

e. Extrapola�ng temperature trends to determine performance limits without water cooling

f. Iden�fying means to ven�late the plenum between op�cal lenses to avoid entrapment of air during vacuum opera�on

These deliverables are expected by four months from date of award, although technical support and design of minor changes may con�nue beyond this date un�l September 30, 2025 (period of performance not to exceed).

These ac�ons will be performed at vendor facili�es.