SATPC0039462 Tab 04 4 SOW.pdf
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- Solicitation number
- 80NSSC25912297Q
About this file
This Statement of Work (SOW) details a NASA research project to manufacture ultrasonically welded single lap shear coupons for assessing bond strength, thermal history, and residual stress. The project involves creating up to 72 ultrasonic welds using various composite materials including AS4/PEEK panels, AS4-PEEK/PEI Hybrid panels, and AS4-PEEK/PEI (OATMEAL) panels, with PEEK or PEI film/mesh energy directors. NASA will provide 12" x 12" panels, which will be machined into 1" x 4" adherends for testing.
The work includes multiple analytical processes: 36 C-scans to assess laminate defects and bondline homogeneity, photomicroscopy on 12 coupons to image cross-sectional weld areas, residual stress measurements using ARAMIS Optical Strain, and temperature validation with Trilion Thermography. A kick-off meeting will discuss measurements made during welding. The project is expected to be completed by February 2026, with a total of 36 test specimens (process development and test coupons) undergoing various analyses to evaluate weld quality and characteristics.
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Statement of Work
The objective of this work is to manufacture a series of ultrasonically welded single lap shear coupons to assess bond strength, thermal history, and residual stress as a function of energy director and prepreg hybridization.
NASA provided materials
• 12” x 12” panels of the below materials will be provided to use as adherends for ultrasonic welding. Adherends shall be 1” x 4” to provide coupons for single lap shear tests.
o AS4/PEEK panels to supply adherends for welding o AS4-PEEK/PEI Hybrid panels to supply adherends for welding o AS4-PEEK/PEI (OATMEAL) panels to supply adherends for welding
• PEEK film or mesh energy director
• PEI film or mesh energy director
Ultrasonic Welding
Up to 144 adherends shall be machined to complete up to 72 ultrasonics welds shall be made, based on the table below:
NDE by thru-transmission C-scan
Single lap shear test coupons shall be inspected by C-scan to assess defects to the laminate and homogeneity at the bondline, for a total of 36 C-scans.
Photomicroscopy
Two process development coupons shall be reserved for Photomicroscopy to image the cross sectional weld area. Photomics will be collected from a total of 12 coupons.
Adherend Material Energy Director
Specimen
(Process Dev.) Specimen (Test) Tot. # Adherends
Tot. # of
Ultrasonic Welds
AS4/PEEK PEEK- thickness 1 6 6 24 12
AS4/PEEK PEEK- thickness 2 6 6 24 12
AS4/PEEK PEI- thickness 1 6 6 24 12
AS4/PEEK PEI- thickness 2 6 6 24 12
LaRC Hybrid Composite none 6 6 24 12
LaRC OATMEAL none 6 6 24 12
Adherend Material Energy Director Specimen (Test) Tot. # of -Cscans
AS4/PEEK PEEK- thickness 1 6 6
AS4/PEEK PEEK- thickness 2 6 6
AS4/PEEK PEI- thickness 1 6 6
AS4/PEEK PEI- thickness 2 6 6
LaRC Hybrid Composite none 6 6
LaRC OATMEAL none 6 6
Residual Stress and Bond-Area Temperature Measurements in conjunction with Trilion
Thermography shall be used validate local temperatures during the welding of test specimen – quantity 36
(process development and test coupons)
ARAMIS Optical Strain shall be used to measure the residual stress of the welds, as a measure of weld quality. A total of 36 measurements shall be made (process development and test coupons)
Kick-off meeting to discuss measurements made during welding.
PERIOD OF PERFORMANCE: We expect this work to complete by February, 2026.
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