SATPC0041752 Tab 07 2 SOW Redacted.pdf

Correlation of Process-Induced Lack of Fusion Defects with Mechanical Performance in

Laser Powder Bed Fusion Inconel 718 Using Integrated In-Situ Monitoring and Computed

Tomography Characterization

Statement of Work (SOW)

The National Aeronautics and Space Administration (NASA), specifically Marshall Space Flight

Center (MSFC) has a need for laboratory-based additive manufacturing (AM), non-destructive evaluation (NDE), and mechanical testing with an independent laboratory to execute the foundational in-situ monitoring (ISM) qualification framework and develop detectability and mechanical sensitivity models for Laser Powder Bed Fusion (LPBF).

The SOW is as follows:

1. The vendor shall have unique capabilities and experience in integrated laser powder bed fusion (LPBF) platforms equipped with advanced in-situ monitoring suites, high-resolution computed tomography (CT) characterization, and NASA-STD-6030 technical requirements.

2. The vendor shall fabricate a minimum of sixty (60) LPBF Inconel 718 (IN718) mechanical test specimens and ten (10) dedicated metallography witness bars, distributed evenly across a baseline and three intentional Lack of Fusion (LOF) defect states.

3. The vendor shall collect layer-wise visible and thermal in-situ monitoring data during all builds to capture part defects and process variations.

4. The vendor shall perform high-resolution X-Ray Computed Tomography (XCT) scanning on all sixty (60) specimens in the as-built or stress-relieved state to establish objective 3D volumetric ground truth of internal defect morphology.

5. The vendor shall extract defect size distributions, spatial locations, and morphology within the build coordinate system to support validation and POD calculations.

6. The vendor shall subject designated specimens to full post-build heat treatments, machine them to ASTM E8/E8M and ASTM E466 specifications, and perform static tensile and high cycle fatigue (HCF) testing.

7. The vendor shall perform full fractography on all failed fatigue specimens to confirm failure origins and correlate them with prior XCT-defect data.

8. The vendor shall deliver spatially registered in-situ, XCT, and mechanical datasets and develop Probability of Detection (POD) models, Probability of False Alarm (PFA) curves, and critical a90/95 flaw sizes aligned with MIL-HDBK-1823A.

9. The vendor shall participate in a technical data review with MSFC subject matter experts to validate spatial registration and preliminary signal-defect correlation findings.

10. The vendor shall grant the Government unlimited rights to all data, reports, test results, and associated documentation generated under this SOW.

11. The vendor shall coordinate with NASA MSFC personnel for peer review and co-authorship on any public documentation or journal articles developed from this data prior to external publication.

Shipping

1. Contractor shall ship required samples to:

Marshall Space Flight Center

Huntsville, AL 35812

Deliverables

1. Fabricated & Tested Specimens (sixty mechanical specimens and ten designated witness metallography bars).

2. Feedstock Certification documentation (powder lot CoC, chemistry, PSD, and morphology reports).

3. Raw & Processed Data (in-situ monitoring exports, XCT defect maps, and mechanical test records in open formats like TIFF, CSV, HDF5).

4. Validation Metrics Report detailing POD, PFA, and a90/95 calculations per MIL-HDBK-

1823A.

5. Final test report & fractography summarizing mechanical performance, failure mechanisms, and signal-to-defect correlations.

6. Technical white paper summarizing the methodologies employed, LOF defect mechanical sensitivity, and in-situ monitoring effectiveness.

7. Monthly technical and financial status reports.

Period of Performance

The tasks shall be conducted over the course of approximately six (6) months, with the duration beginning upon initiation of contract award.