Statement_of_Work.pdf

SCIENTIST/ENGINEERING SUPPORT FOR MEASUREMENT SCIENCE FOR

ADDITIVE MANUFACTURING PROGRAM

STATEMENT OF WORK

I. BACKGROUND

Metal parts manufactured by selective laser melting (SLM) are widely known to exhibit undesired characteristics such as high levels of residual stresses and distortion, delamination of layers, porosity, shrinkage, poor surface finish, dimensional and form errors. To address these issues, the Engineering Laboratory and Physical Measurement Laboratory at the National

Institute of Standards and Technology (NIST) are collaborating on an Additive Manufacturing

Metrology Testbed (AMMT). This testbed is a complex SLM platform that will enable in-depth research into the laser-based additive manufacturing (AM) process including traceable radiometric temperature measurements, design and testing of various on-line process monitoring solutions, and design and testing of feedback process control solutions. The in-depth and high-fidelity data acquired on this testbed will provide quantitative relationships between the input parameters, process signatures, and product qualities to enable design and implementation of control solutions, including ways to minimize and mitigate above-mentioned undesired characteristics, enabling rapid process qualification. Measurement and control methodologies and results will be disseminated to the academic, industrial, and government research communities to further the physical understanding laser-based AM processes and promote development of new generation of AM standards.

II. SCOPE OF WORK

a. OBJECTIVES/PURPOSE

The Contractor shall support the research and development objectives of the Intelligent Systems

Division at NIST related to Measurement Science for Additive Manufacturing (MSAM) program. Specifically, the Contractor shall develop measurement and control strategies to minimize residual stress induced SLM part distortions as well as to enable rapid process qualification utilizing in-process monitoring techniques.

b. GENERAL:

The Contractor shall provide all support for project oversight, administration and technical execution. The Contractor is responsible for maintaining accurate records of project activities.

c. TASKS:

The Contractor shall complete the following tasks during the Base Year:

Task 1: Carry out a literature review and analysis of the previous research of residual stresses resulting from SLM processes and the identification and selection of promising technical approaches to reduce them. At least five relevant technical papers shall be included in the review and analysis. The Contractor shall conduct progress review meetings bi-monthly and present PowerPoint slides on progress made, tasks to be completed in the next reporting period, conclusions, and any technical recommendations.

Task 2: Development of a concept for in-situ heat treatment of SLM parts to reduce residual stress induced distortions. The Contractor shall develop a technical report for this task.

Task 3: Analysis of at least two of the latest technical approaches used for the quality control of SLM processes and parts fabricated by SLM processes. The Contractor shall present

PowerPoint slides on progress made, tasks to be completed in the next reporting period, conclusions, and any technical recommendations.

Task 4: Development of a new concept for in-process monitoring of SLM parts with feedback control to optimize the quality of manufactured products and process qualification with the possibility of creating real-time reports and a “passport of quality” of manufactured products, providing estimated porosity and location of probable defects. The Contractor shall develop a technical report for this task.

The Contractor shall complete the following tasks during Option Year I:

Task 5: Development of a design of experiments and a simplified computer model, carrying out the numerical simulation for a preliminary assessment of the effects of selected process parameters on product quality. The Contractor shall conduct progress review meetings bi-monthly and present PowerPoint slides on progress made, tasks to be completed in the next reporting period, conclusions, and any technical recommendations.

Task 6: Elaboration of example of realization, including specific requirements and additional tools, required for the verification of the computer model in the laboratory test bed conditions

(such as AMMT at NIST or other experimental setups). The Contractor shall develop a technical report for this task.

Task 7: Develop detailed recommendations for the implementation of the proposed system on-line monitoring of the SLM processes and parts on the basis of the experimental setup such as AMMT at NIST. The Contractor shall present PowerPoint slides on progress made, tasks to be completed in the next reporting period, conclusions, and any technical recommendations. The Contractor shall also develop a technical report for this task.

The Contractor shall complete the following tasks during Option Year II:

Task 8: Development of a design of experiments for verification of the method of reducing residual stresses, including the comparative analysis of obtained results, and method of optimization to improve its efficiency. The Contractor shall conduct progress review meetings bi-monthly and present PowerPoint slides on progress made, tasks to be completed in the next reporting period, conclusions, and any technical recommendations. The

Contractor shall also provide a technical report for this task.

Task 9: Evaluation of the on-line monitoring system implemented by NIST, including analysis of the experimental results obtained by NIST researchers; and suggestions on the optimization of the system to improve its efficiency. The Contractor shall conduct progress review meetings bi-monthly and present PowerPoint slides on progress made, tasks to be completed in the next reporting period, conclusions, and any technical recommendations.

The Contractor shall also provide a technical report for this task.

III. DELIVERABLES

Number/

Reference Description Format Quantity Due Date

1 Progress review meetings with the key researchers of NIST team.

e-meetings (e.g., WebEx), Powerpoint slides

Bimonthly No later than

(NLT) 2nd week of the month

2 Report describing the concept of in-situ heat treatment of SLM parts

MS Word via e-mail One (1) NLT twelve (12) months after award of task order

3 Progress review meetings with the key researchers of NIST team.

e-meetings (e.g., WebEx), Powerpoint slides

Bimonthly NLT 2nd week of the month

4 Report describing the new concept for in-process monitoring of SLM parts with feedback control and process qualification.

MS Word via e-mail One (1) NLT twelve (12) months after award of task order

(Option 1)

Progress review meetings with the key researchers of NIST team.

e-meetings (e.g., WebEx), Powerpoint slides

Bimonthly No later than

(NLT) 2nd week of the month

(Option 1)

Report describing realization, including specific requirements and additional tools, required for the proof of concept in the laboratory test bed conditions

MS Word via e-mail One (1) NLT twelve

(12) months after award of task order

(option 1)

Progress review meetings with the key researchers of NIST team.

e-meetings (e.g., WebEx), Powerpoint slides

Bimonthly No later than

(NLT) 2nd week of the month

(option 1)

Report describing detailed recommendations for the implementation of the proposed system on-line monitoring of the SLM processes and parts on the basis of the experimental setup such as AMMT at NIST

MS Word via e-mail One (1) NLT twelve

(12) months after award of task order

(option 2)

Progress review meetings with the key researchers of NIST team.

e-meetings (e.g., WebEx), Powerpoint slides

Bimonthly No later than

(NLT) 2nd week of the month

(option 2)

Final technical report describing experimental verification of the method of reducing residual stresses, including the comparative analysis of obtained results, MS Word via e-mail One (1) NLT twelve

(12) months after award of task order

Number/

Reference Description Format Quantity Due Date and method of optimization to improve its efficiency

(Option 2)

Progress review meetings with the key researchers of NIST team.

e-meetings (e.g., WebEx), Powerpoint slides

Bimonthly No later than

(NLT) 2nd week of the month

(option 2)

Final technical report describing Evaluation the on-line monitoring system, including analysis of the experimental results; and suggestions on the optimization of the system to improve its efficiency

MS Word via e-mail One (1) NLT twelve

(12) months after award of task order

IV. PERFORMANCE REQUIREMENT SUMMARY

Desired Output Required Service

Performance

Standard Monitoring Method

Report describing the new concept of in-situ heat treatment of SLM parts

Writing the report with intermediate section drafts available for review by

NIST staff.

Report is written in clear and understandable format.

Documentation shall be reviewed by NIST project staff and NIST TPOC to ensure with performance standards

Report describing the new concept for in-process monitoring of SLM parts with feedback control and process qualification.

Writing the report with intermediate section drafts available for review by

NIST staff.

Report is written in clear and understandable format.

Documentation shall be reviewed by NIST project staff and NIST TPOC to ensure with performance standards

Report describing realization, including specific requirements and additional tools, required for the proof of concept in the laboratory test bed conditions

Writing the report with intermediate section drafts available for review by

NIST staff.

Report is written in clear and understandable format.

Documentation shall be reviewed by NIST project staff and NIST TPOC to ensure with performance standards

Report describing detailed recommendations for the implementation of the proposed system on-line monitoring of the SLM processes and parts on the basis of the experimental setup such as AMMT at

NIST

Writing the report with intermediate section drafts available for review by

NIST staff.

Report is written in clear and understandable format.

Documentation shall be reviewed by NIST project staff and NIST TPOC to ensure with performance standards

Final technical report describing experimental verification of the method of reducing residual stresses, including the comparative analysis of obtained results, and method of optimization to improve its efficiency

Writing the report with intermediate section drafts available for review by

NIST staff.

Report is written in clear and understandable format.

Documentation shall be reviewed by NIST project staff and NIST TPOC to ensure with performance standards

Desired Output Required Service

Performance

Standard Monitoring Method

Final technical report describing Evaluation the on-line monitoring system, including analysis of the experimental results; and suggestions on the optimization of the system to improve its efficiency

Writing the report with intermediate section drafts available for review by

NIST staff.

Report is written in clear and understandable format.

Documentation shall be reviewed by NIST project staff and NIST TPOC to ensure with performance standards

V. PERIOD OF PERFORMANCE

The period of performance shall be one (1) year from date of award. The Government may exercise up to two (2) one-year options.

VI. PLACE OF PERFORMANCE

The place of performance shall be the contractor’s facility. However, the work requires close coordination of activities with ongoing NIST research on process monitoring and control of SLM processes. Such coordination shall require the contractor to have continuous/periodic communication with NIST researchers and visit(s) to NIST laboratories to work with NIST researchers as needed. The NIST Technical Point of Contract (TPOC) will provide at least 15 days of notification to the Contractor regarding the need for a WebEx and/or onsite visit to the

NIST campus at Gaithersburg, MD.

VII. OWNERSHIP

All property, data and information provided by the Government in the performance of this task remains the property of the Government and shall be surrendered to the government upon completion or termination of this requirement. Likewise, all deliverables generated under this requirement remain the property of the Government.

VIII: INSPECTION/ACCEPTANCE

The NIST TPOC will provide comments on each deliverable within 14 calendar days from receipt of a given deliverable. The Contractor shall make any needed changes to the reports within 14 calendar days from receipt of electronic or written comments from the NIST TPOC.

The NIST TPOC will provide written notification when a deliverable is accepted.

IX. TRAVEL

The Contractor shall be reimbursed for periodical trips to NIST to consult with NIST researchers and observe experiments conducted at NIST by NIST staff.

Actual travel expenses will be reimbursed in accordance with the Federal Travel Regulations

(FTR) and must be pre-approved by the NIST TPOC.

X. CONTRACTOR’S MINIMUM QUALIFICATIONS

The contractor shall have at least a Ph.D. degree or higher in the technical sciences. The contractor shall also have at least ten years of experience in metal additive process and equipment development and related research as well as a proven track record in metal additive manufacturing.