SOW.pdf

STATEMENT OF WORK

Development of Oscillating Heat Pipes for Leading Edge Thermal Protection System (TPS) Materials

June 2023

National Aeronautics and Space Administration Ames Research Center Moffett Field, California

OHP Fabrication | OHPACA Project Version: Rev 1

Table of Contents

1.0 Background

2.0 Purpose and Scope

3.0 Project Structure

4.0 Contract Line Item Numbers

5.0 Applicable Documents

6.0 Task Description

7.0 Schedule

8.0 Government Furnished Equipment, Property, or Information

9.0 Travel

10.0 Period of Performance

11.0 Point of Contact (P.O.C) Information

1.0 Background

Requirements of next generation commercial Low Earth Orbit (LEO) and Department of Defense DOD hypersonic vehicles, dictate the need for robust thermal management solutions. Recent advancements in refractory additive manufacturing technology make available novel integrated thermal management systems capable of operating at extreme temperatures. One such system, Oscillating Heat Pipes (OHP’s), are a potentially disruptive technology to a wide range of NASA applications. NASA Ames Research was recently selected to advance OHP’s for commercial leading-edge applications in partnership with Lockheed Martin through an Announcement of Collaboration Opportunity (ACO). This project is called the Oscillating Heat Pipe for Aero-entry and Commercial Applications (OHPACA).

2.0 Purpose and Scope

The purpose of this Statement of Work (SOW) is to define the tasks, deliverables, and services associated with NASA Ames Research Center’s (ARC) development of OHP’s in support of the OHPACA project.

3.0 Project Structure

The contractor shall provide all labor, materials, facilities, service, equipment, analysis and management necessary to complete all tasks.

This SOW is broken up into three phases. Each phase has a key milestone at the end. The phasing and associated task sequencing is intended to provide a logical progression in the planning, design, testing, fabrication, and delivery of the OHP’s to NASA ARC. Phases are summarized in Table 1Table 1.

Table 1: OHPACA SOW Phase Overview

Phase Phase Overview Key Milestone

Phase A

Provide engineering design and analysis support of prototype and subassembly OHP’s. Define processes and techniques for the filling and sealing of OHP’s. Define basic testing approaches of OHP’s.

Design review

Phase B Procure working fluid (e. g. lithium), fill, seal and deliver Qty

9 prototype OHP’s designed in Phase A. Perform basic testing of prototype OHP’s.

Delivery and Hardware Acceptance Review of

OHP Prototypes

Phase C Procure working fluid (e.g., lithium), fill, seal and deliver Qty. 5 arc jet subassembly models designed in Phase A.

Perform basic testing of OHP’s.

Delivery and Hardware Acceptance Review of OHP Subassemblies

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4.0 Contract Line Item Numbers

The effort described by this SOW shall be completed when all subcontract Contract Line Item Numbers (CLINS), defined in Table 2Table 2, are complete; and when all items in the Subcontract Data Requirements List (CDRL), as defined in section Error! Reference source not found.11, and all deliverables and effort specified in the subcontract have been accepted and approved by NASA Ames Research Center (ARC).

Table 2: Contract Line Item Numbers (CLINS)

Project Phase

Line Item # Item Deliverable Part

# Qty. Delivery Date

Phase A 1 Phase A Data Package Data Package N/A N/A TBD

Phase B 2 Phase B Data Package & Prototype OHP Delivery Data Package N/A N/A TBD

Phase C 3 Phase C Data Package & Subassembly OHP Delivery Data Package N/A N/A TBD

5.0 Applicable Documents

The documents for this IAA include the following listed below:

Determination & Findings (D&F) Statement of Work (SOW) JA22 Ames Routing Slip NF 1707 Form Independent Government Cost Estimate (IGCE) Quote from vendors 7600A & 7600B NIPR Form

6.0 Description of Tasks and Technical Requirements

This section provides detailed descriptions of all tasks. Tasks are linked directly to CLIN’s defined in Table 2.

6.1 CLIN #1: Phase A Data Package

6.1.1 CLIN #1: Technical Requirements

Technical requirements of CLIN#1 are listed below:

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Contractor shall provide engineering support of OHP designs for the proposed vehicle and mission requirements.

Contractor shall provide design recommendations to the proposed OHP designs that enable sealing and filling.

Contractor shall define processes and techniques for the filling and sealing of proposed OHP design.

Contractor shall define testing approach that verifies sealing and operation of OHP’s through benchtop testing. Testing shall satisfy the following settings:

o Max heater temperature: 1000-1200° C (TBC) o Heating heat flux above 1000 °C: 20 w/cm^2 (TBC) o Total heat input into OHP (not counting losses): 1500 w (TBC)

6.1.2 CLIN #1: Deliverables

Contractor shall provide and present a summary presentation at the projects OHP design review.

This design review will be used to obtain stakeholder concurrence with the completeness and consistency of the project’s preliminary design in satisfying mission requirements and project goals. The design review will also act to determine the projects’ readiness to proceed to phase B.

Format: The format of the summary presentation will be defined by the Contractor. A slide type presentation is recommended.

Content: The content of the Design Review Data Package shall include:

1. Design concept (with focuses on any recommended updates), including:

a. General design overview and results of applicable analyses

b. Procedure for filling and sealing

2. Details of proposed testing that verify operation of OHP’s

3. Schedule, including:

a. Parts and material receipt

b. Fabrication (filling and sealing)

6.2 CLIN #2: Phase B Data Package & Prototype OHP Delivery

6.2.1 CLIN #2: Technical Requirements

Technical Requirements of CLIN#2 are:

Contractor shall procure OHP working fluid and other hardware necessary to seal and fill prototype OHP’s

Contractor shall attempt to fill and seal , seal, and deliver Qty 9 OHP prototypes.

o Each prototype will have a running length less than 10x3 in2 (TBC) o Given the developmental nature of this work, some failures during filling, sealing, and charging are to be expected. The contractor should make every effort to develop processes that minimize these failures.

Contractor shall perform operational testing defined in CDRL #1 on Qty 9 OHP prototypes and provide associated documentation. One Prototype will undergo Fluid Optimization (chemistry selection, and liquid fill fraction) and subsequent Verification Testing. The balance of eight Prototypes will undergo acceptance testing.

Contractor shall provide recommended design updates and lessons learned to be implemented in Phase C for subassembly units.

Contractor shall deliver Qty. 6 OHP prototypes which have passed acceptance testing to confirm the parts are charged and sealed appropriately.

6.2.2 CLIN #2: Deliverables

The deliverables from Phase 2 are:

Qty. 9 filled and sealed OHP prototypes o Unsealed OHP prototypes shall be provided by NASA.

o NASA shall provide contractor a copy of the final manufacturing design files, for review and concurrence, prior to release for additive manufacturing

A presentation at the projects OHP Prototype Hardware Acceptance Review (HAR) which summarizes the filling levels and sealing processes, and test data that supports verification of operation. The HAR will determine the projects’ readiness to proceed to Prototype testing and Phase C.

Format: The format of the summary presentation will be defined by the Contractor. A slide type presentation is recommended.

Content: The content of the HAR Data Package shall include:

1. Summary of testing performed that demonstrates operation

2. Recommendations and lessons learned that will feed forward to future OHP designs.

6.3 CLIN #3: Phase C Data Package & Subassembly OHP Delivery

6.3.1 CLIN #3: Technical Requirements

Technical requirements of CLIN #3 are:

Contractor shall procure OHP working fluid and other hardware necessary to seal and fill subassembly OHP’s

Contractor shall attempt to fill and, seal and deliver Qty 5 OHP subassemblies.

o Given the developmental nature of this work, some failures during filling, sealing, and charging are to be expected. The contractor should make every effort to develop processes that minimize these failures.

Each subassembly will have a wetted running length less than 15x6 in2 (TBC) Contractor shall perform operational testing defined in CDRL #1 on Qty 5 OHP subassemblies and provide associated documentation. One subassembly will undergo

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Fluid Optimization (chemistry selection, and liquid fill fraction) and subsequent Verification Testing. The balance of four subassemblies will undergo acceptance testing.

Contractor shall deliver Qty. 4 OHP subassemblies which have passed acceptance testing to confirm the parts are charged and sealed appropriately along with .

Contractor shall provide recommended design updates and lessons learned to be implemented in the future.

6.3.2 CLIN #3: Deliverables

The deliverables from Phase C are:

Qty. 5 filled and sealed OHP subassemblies o Unsealed OHP subassemblies shall be provided by NASA.

o NASA shall provide contractor a copy of the final manufacturing design files, for review and concurrence, prior to release for additive manufacturing.

A presentation at the projects OHP Subassembly Hardware Acceptance Review (HAR) which summarizes the filling levels and sealing processes, and test data that supports verification of operation. The HAR will determine the projects’ readiness to proceed to subassembly arc jet testing.

Format: The format of the summary presentation will be defined by the Contractor. A slide type presentation is recommended.

Content: The content of the HAR Data Package will include:

1. Summary of testing performed that demonstrates operation

2. Recommendations and lessons learned that will feed forward to future OHP designs.

7.0 Schedule

Table 1. Schedule for Deliverables Activity Start Date Responsible Phase A Mission Requirement Definition July 2023 NASA Phase A Design Review October 2023 (TBC) NASA & Subcontractor Phase B: OHP unfilled prototype delivery December 2023 (TBC) NASA Phase B: OHP Prototype HAR March April 2024 (TBC) Subcontractor Phase C: OHP unfilled subassembly delivery July 2024 (TBC) NASA Phase C: OHP subassembly HAR October November 2024

(TBC)

Subcontractor

8.0 Government Furnished Property, Material, Equipment, or Information (GFP/M/E/I)

Qty 9 Unfilled OHP prototypes Qty 5 unfilled OHP subassemblies

9.0 Travel

All travel costs incurred will be in accordance with the Joint Travel Regulations (JTR).

NASA will send 1 2 staff to witness prototype and subassembly tests.

Subcontractor may choose to send 1 2 staff to witness arc jet testing of OHP subassemblies.

10.0 Period of Performance

The period of performance for this effort shall be from July 15 2023 to January 30, 2025.

11.0 Point of Contact (P.O.C) Information

NASA Ames Point of Contact (POC):

NASA POC:| Thermal Protection Materials and Systems Branch Address: Building 234 Room 117, NASA Ames Research Center, Moffett Field, CA 94035

NASA Ames Contract Specialist:

NASA Ames Contract Specialist:

Email:

Address:

Design for Thermal Mechanical Performance to meet specifications Risk Level 2 3 Comments Actual performance of working fluids may be dependent on geometric constraints, which have not yet been fully defined. While modeling development for high temperature OHPs has been conducted over multiple SBIR programs, some moderate risk still remains with applicability to new geometries.

Producibility Risk Level 3 4

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Comments Lab processes that inherently carry some moderate risk are: filling working fluid and final sealing. The success of filling with working fluid, without the introduction of non condensable gas (NCG) or contamination (e.g. oxygen, moisture), can likely be verified through subsequent thermal performance testing. The higher risk item is the final seal, which requires a pinch and weld procedure to be performed, without introducing NCGs or contamination. This procedure has been previously developed for high temperature metals and super alloys, and is expected to be applied similarly to this work. However, there is inherent risk in this procedure that will be addressed through coupon level demonstrations prior to executing on full scale hardware. If there is any fallout, we would expect this to be the source, and all measures will be taken to carefully audit this procedure and only continue, based on agreed upon success criteria (e.g., thermal performance test before and after final seal)

Verifiable Performance Risk Level 2 3 Comments Using existing test facilities, TAT expects to develop electric heaters that can verify performance of the OHPs in a way that is expected to translate to customer's test configurations.

Timing Risk Risk Level 3 4 Comments Support hardware will have to be spun up early, due to relatively short overall timeline for 2 build cycles. Request for 4 months minimum, per cycle as submitted.

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