SATPC0040733 Tab 04 4 SOW.pdf

Statement of Work (SOW) for

Characterization and Fatigue Testing of Oxide Dispersion Strengthened Alloys supporting Additively Manufactured Handbook

The National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) continues to foster public-private partnerships with industry and academia. In support of STMD, NASA is partnering with Auburn University to advance additive manufacturing (AM) technologies. This collaboration focuses on new AM material development, characterization, data dissemination, and process capabilities, including surface enhancements and in-situ monitoring for AM materials. This SOW aims to complete all documentation, reporting, and data dissemination for AM alloy characterization initiated under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Optimized and Repeatable Component using Additive (ORCA), and AM for Propulsion projects. The work will support NASA-led technology development projects, particularly in aerospace applications such as liquid rocket propulsion systems and large-scale space exploration structures.

The tasks are as follows:

1. Characterization and Data Analysis: The contractor shall complete detailed characterization and analysis of mechanical test data from additively manufactured samples provided.

2. Literature Review: The contractor shall conduct a literature review and summary for each alloy listed in Table 1. Please note some of these are new alloys and may not have any public information available.

3. Data Summary and Documentation: The contractor shall summarize, analyze, and document all mechanical test and characterization results.

4. Initial Characterization: The contractor shall perform initial characterization using techniques such as scanning electron microscopy (SEM), computer tomography (CT) scanning, and optical microscopy. Additional techniques such as microhardness, grain size evaluations, etching, and residual stress measurements shall be considered to enhance the dataset.

5. Thermal State Characterization: The contractor shall characterize materials in the as-built state and after each heat treatment stage, optimizing heat treatment as necessary.

6. Post-Mechanical Test Fractography: The contractor shall analyze postmortem tensile and fatigue specimens to determine failure mechanisms at various test temperatures.

7. Mechanical Testing: The contractor shall complete room temperature fatigue testing on a minimum of sixty (60) samples for the GRX-810 reuse study. The samples will be provided per ASTM geometry in the as-built condition (no machining in the gage section). Low cycle fatigue (LCF) in strain control (or load control as discussed with the NASA contact) and high cycle fatigue (HCF) in load control shall be completed on samples to failure. The conditions will be agreed upon by NASA and contractor before testing is initiated.

8. Data Summary Sheet: The contractor shall provide a summary data sheet incorporating all tensile and fatigue test data, including any issues with data.

9. Organized Dataset: The contractor shall maintain an organized dataset in an accessible online database, including summary and raw test data and relevant post-test characterization data.

10. Collaboration with Test Service Companies: The contractor shall work with third-party test service companies to address testing questions and non-conformances.

11. Detailed Reporting: The contractor shall complete detailed reports in the form of NASA Technical Memorandum, journal articles, conference papers, or other publicly available reports for each alloy and task listed in Table 1, following approval by NASA export control.

12. Regular Meetings: The contractor shall attend bi-monthly meetings to discuss updates, results, and progress with NASA personnel. Additional meetings may be necessary, as required.

Table 1: Material Documentation and Summary Reports

Material No. Material Report List

1 GRX-810 Low Cycle Fatigue behavior of recycled powder (25x) 2 Alloy 754-ODS Temperature-dependent fatigue behavior of Alloy 754-ODS 3 ORCAlloy-21 Temperature-dependent fatigue behavior of ORCAlloy-21

Assumptions

NASA will provide all samples for testing in the as-built and heat-treated condition, as necessary.

NASA will complete mechanical testing of samples with a 3rd party vendor and provide tabulated results, along with tested samples, to contractor for full characterization.

Contractor will complete fatigue testing of (60) room temperature samples for the GRX-810 recycled powder study.

NASA will complete characterization of powder after each reuse for the GRX-810 material listed in Table 1 and provide data for reporting.

NASA will provide material certification and build parameters (as feasible).

A minimum of one paper/report will be completed per alloy with the option for additional papers.

Any additional testing (i.e. chemistry) should be coordinated with NASA contacts.

Shipping

1. Contractor shall ship any deliverables as needed to:

Marshall Space Flight Center Central Receiving, Bldg 4631 Attn: Paul Gradl Huntsville, AL 35812

Period of Performance (POP)

9 months from authority to proceed (ATP)

Deliverables

1. Data summary sheets related to tensile and fatigue properties for each of the alloys provided in table 1.

2. Organized raw data set for mechanical tests, microscopic characterization, and any other characterization technique used to investigate each sample of the materials outlined in Table 1.

3. A draft or published report for each material outlined in Table 1.