SOW for IAD IDIQ Final 31Jan22.pdf

EXHIBIT A – STATEMENT OF WORK

INFLATABLE AERODYNAMIC DECELERATORS

INTRODUCTION AND BACKGROUND

Inflatable aerodynamic decelerators (IAD) represent a cross‐cutting technology being developed to achieve improved atmospheric entry capabilities, enabling delivery of large mass payloads in a variety of NASA applications. Successful development of the IAD technology can lead to an improved mission flexibility and entry, descent, and landing (EDL) timeline, yielding increased landed mass, improved delivery accuracy, and/or ability to land at higher altitude.

Future high‐mass robotic and human exploration missions that could benefit from the use of IAD technology include Mars robotic, Mars human, Venus robotic Low Earth Orbit/International Space Station, Near Earth Object return‐robotic, and terrestrial robotic missions.

In 2012, the third Inflatable Reentry Vehicle Experiment (IRVE‐3) was launched on a sounding rocket out of Wallops Flight Facility with a goal of demonstrating the concept of inflatable reentry vehicles. During the IRVE‐3 flight, the aeroshell inflated as designed to a diameter of 3m and maintained stability through hypersonic reentry and the supersonic, transonic and subsonic flight regimes. Following IRVE‐3, ground development has continued with fabrication and testing of a 6m diameter IAD with improvements to thermal and structural performance.

The current Low‐Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) project is developing a reentry vehicle with a 6m diameter IAD that is scheduled for a flight test in 2022.

Potential NASA and commercial mission applications will require IAD of 10‐20m in diameter.

IAD designs should address mission requirements for aerocapture and/or EDL, which may include hypersonic, supersonic, transonic and subsonic regimes, depending upon the specific application. Development activities may also include integration with various flight vehicle configurations, stowage arrangements, deployment methods, inflation systems, and instrumentation for system and flight data measurements. A complete IAD aeroshell system includes the Inflatable Structure (IS), Flexible Thermal Protection System (FTPS), stowage restraint system, inflation system, and integration to space vehicle structure. Task orders are planned to begin with ground development and testing efforts to demonstrate increased structural load and thermal performance capabilities and then progress to IAD articles for flight demonstrations. As IAD scale increases, inflation systems driven by gas generators are expected to provide mass advantages over current systems which use compressed gas.

SCOPE AND OBJECTIVES

This Statement of Work (SOW) defines the scope for the development of IAD technology for space vehicle aerocapture and EDL for atmospheric entry applications in hypersonic, supersonic, transonic and subsonic regimes. Task orders issued against this SOW may include design, manufacturing, and testing for materials, components, subassemblies, concept demonstration articles, engineering development units, and flight articles.

The SOW is divided into three Technical Tracks, as follows:

Technical Track A: Inflatable Structures Design, Fabrication (including Aeroshell Integration), and Testing

Technical Track B: Flexible Thermal Protection Systems Design, Fabrication (including Aeroshell Integration), and Testing

Technical Track C: Gas Generator Inflation System Design, Manufacturing, and Testing

The contractor shall furnish all personnel, facilities, equipment, material, supplies, and services, except as may be expressly set forth in the contract task orders as Government furnished, and otherwise do all things necessary to, or incident to, perform and provide the work efforts described in this Exhibit A. The contractor shall perform task orders that are issued by a NASA Contracting Officer. This contract may be used to support all NASA Centers that require work within the scope of this SOW.

TECHNICAL TRACKS

TECHNICAL TRACK A:

INFLATABLE STRUCTURES (IS) DESIGN, FABRICATION (INCLUDING

AEROSHELL INTEGRATION), AND TESTING

Background:

The primary objective is to increase the scale of IS to 10‐20m in diameter. Alternate IS concepts to improve capabilities for IAD performance and flight control are included as a secondary objective. The alternate concepts may include deformable or morphing structures, trim tabs, tension cones, and cascading structures with an initial geometry that expands to a larger geometry during flight. The effort will progress from conceptual design, concept demonstration, fabrication and testing of ground test articles to fabrication and testing flight articles.

Description of Task Order Content:

A.1 Inflatable Structures: The Contractor shall provide design, manufacturing, and testing of IS including, but not limited to, the following work that may be written as Task Orders (TOs):

- Develop conceptual and detailed designs, and construction methods, of IS. The contractor shall provide a design as specified in the TO that may include, but is not limited to, materials selection, materials development, Computer‐Aided Design (CAD) models, structural analysis models, and pertinent drawings.

- Fabricate and deliver IS components. IS components will be specified in the TO and may include, but are not be limited to, fabrication and delivery of test coupons, ground article assemblies, and flight unit assemblies.

- Integrate TO specified instrumentation into the IS. Instrumentation may include, but are not limited to, the measurement of temperature, strain, shape, and internal pressure.

- Provide mass estimates and actual measurements which may include, but are not limited to, estimates of the mass breakdowns of the constituents of individual components, completed structural assembly mass, interim masses of components, and final as‐built mass properties of the assembly.

- Investigate the advancement of the structural design to reduce mass, improve packing efficiency, increase structural stiffness, increase fault tolerance, develop damage repair techniques increase component durability, and increase system reliability.

- Develop methods and procedures to improve fabrication techniques that reduce integration complexities or improve system reliability, fabrication efficiency, and/or repeatability.

- Develop methods to improve integration of required sensors compatible with the

IS.

- Develop methods to improve mechanical interfaces with the rigid structure and mechanical interfaces with the FTPS.

- Develop conceptual and detailed design of flexible and compactible hoses and fittings for inflation of IS. The contractor shall provide a design as specified in the TO that may include, but is not limited to, materials selection, CAD models, structural analysis models, and pertinent drawings.

- Fabricate and deliver Inflation System assemblies. Inflation System assemblies may be for use in ground test articles or flight units.

- Develop test methods and equipment for environmental testing of components, subcomponents, subassemblies, and/or assemblies at scale

- Develop methods and equipment for non‐destructive evaluation and inspection of components, subcomponents, subassemblies, and/or assemblies at scale.

- Conduct testing for subcomponent, component or system level development tests as specified in the TO.

o This may include, but is not limited to, materials, construction techniques, interfaces, stowage, deployment, instrumentation functionality, or leakage o Develop written test plans and procedures o Perform a technical analysis of test results and prepare corresponding test documentation and reports

A.2 Aeroshell Integration and Testing: The Contractor shall provide integration and testing for inflatable aeroshells including, but not limited to, the following work that may be written as Task Orders (TOs):

Aeroshell Integration

- Perform assembly and integration of the sub‐elements of the IAD to form a complete aeroshell assembly (or components thereof) and integration to vehicle interface, as specified in the TO. The contractor shall provide pertinent documentation associated with the assembly and integration including, but not limited to, CAD models and pertinent drawings.

- Develop conceptual and detailed design for integration, integration processes, inspections, and ground support equipment as specified in the TO.

- Develop methods to improve assembly and integration techniques and reduce complexities.

- Develop methods to improve mechanical interfaces between the integrated aeroshell and vehicle centerbody.

- Provide written verification of integration requirements as specified in the TO.

This may include, but is not limited to, proof of inspection, as‐run procedures, as‐ built drawings, and calibration data.

Packing and Flight Restraint:

- Design, fabricate, and deliver flight restraints assemblies, which may be used during ground or flight testing.

- Develop packaging approaches for stowing IAD for flight testing or ground testing requiring a deployment.

- Develop handling techniques and equipment for maneuvering and manipulating the large‐scale assemblies at various stages of development, hard packing for flight, and light packing for storage and transport.

- Develop flight restraint designs to improve mass of restraint and deployment system, increase fault tolerance, or increase system reliability.

- Provide mass estimates and actual mass measurements, which may include, but are not limited to, mass breakdowns of the constituents of individual components, estimates of the completed flight restraint assembly mass, interim masses of components, and final as‐built mass of the assembly.

Testing of Integrated Aeroshell:

- Perform tests of the integrated aeroshell that may include, but not limited to:

o Packing into a stowed volume o Launch environment (vibration, ascent depressurization) testing of the packed aeroshell o Cruise environment (Vacuum/thermal cycling exposure) testing o Deployment and inflation o Load tests of deployed aeroshell o Leak tests

- Design and fabricate test integration and fixtures and equipment including instrumentation to obtain test measurements.

- Develop written test plans and procedures.

- Perform a technical analysis of test results and prepare corresponding test documentation and reports.

- Provide onsite technical support for system level tests that are conducted at NASA or other facilities.

TECHNICAL TRACK B:

FLEXIBLE THERMAL PROTECTION SYSTEMS (FTPS) DESIGN,

FABRICATION (INCLUDING AEROSHELL INTEGRATION), AND TESTING

Background:

The primary objective is to increase the scale of IAD FTPS to 10‐20m in diameter. FTPS to suit alternate IAD concepts to improve capabilities for IAD performance and flight control will be a secondary objective. These concepts may include the application of FTPS for deformable or morphing structures, trim tabs, tension cones, and cascading structures with an initial geometry that expands to a larger geometry during flight. The effort will progress from conceptual design, concept demonstration, fabrication and testing of ground test articles to fabrication and testing of flight articles.

Description of Task Order Content:

B.1 Flexible Thermal Protection Systems: The Contractor shall provide design, manufacturing, and testing of FTPS including, but not limited to, the following work that may be written as Task Orders (TOs):

- Develop conceptual and detailed designs, and construction methods, of FTPS based on government specified materials and layups set forth in the TO. The construction design specified in the TO may include, but is not limited to, manufacturing, testing, integration details and pertinent drawings. Drawing details required will also be specified in the TO and may include, but are not limited to, construction stitching, weave type, close‐out, and integration.

- Fabricate and deliver FTPS components. FTPS components will be specified in each TO and may include, but are not limited to, test coupons, ground article assemblies, or flight unit assemblies.

- Integrate instrumentation into the FTPS fabrication construction of a TO specified layup. Instrumentation integrated into FTPS will be specified in each TO and may include, but are not limited to, thermal flux, surface temperature, strain, shape, and surface pressure instrumentation.

- Provide mass estimates and actual mass measurements which may include, but are not limited to, mass breakdowns of the constituents of individual components, estimates of completed FTPS assembly masses, interim mass estimates of components, and final as‐built mass of the assembly.

- Investigate the advancement of FTPS construction techniques including, but not limited to, mass reduction, improved packing efficiency, increased thermal resistance, increased fault tolerance, damage repair, component durability, or increased system reliability.

- Develop methods to improve fabrication techniques that reduce integration complexities or improve system reliability.

- Develop methods to improve integration of required sensors compatible with the

FTPS.

- Develop methods to improve mechanical interfaces with the rigid structure and mechanical interfaces with the IS to meet system requirements.

- Develop handling techniques and equipment for maneuvering and manipulating the large‐scale subassemblies and assemblies at various stages of development and for light packing for storage and transport.

- Conduct evaluations of advanced materials for improved system development.

- Conduct testing for subcomponent, component or system level development tests as specified in the TO.

o This may include, but is not limited to, material thermal performance, construction techniques, interfaces, stowage, deployment, or instrumentation functionality.

o Develop written test plans and procedures.

o Perform a technical analysis of test results and prepare corresponding test

B.2 Aeroshell Integration and Testing: The Contractor shall provide or support integration, and testing of inflatable aeroshells including, but not limited to, the following work that may be written as Task Orders (TOs):

Aeroshell Integration

- Perform assembly and integration of the sub‐elements of the IAD to form a complete aeroshell assembly or components thereof and integration to vehicle centerbody, as specified in the TO. The contractor shall provide pertinent documentation associated with the assembly and integration including, but not limited to, CAD models and pertinent drawings.

- Develop conceptual and detailed design for integration, integration processes, inspections, and ground support equipment as specified in the TO.

- Develop methods to improve assembly and integration techniques and reduce complexities.

- Develop methods to improve mechanical interfaces between the integrated aeroshell and vehicle centerbody.

- Provide written verification of integration requirements as specified in the TO.

This may include, but is not limited to, proof of inspection, as‐run procedures, as‐ built drawings, and calibration data.

Testing of Integrated Aeroshell:

- Support tests of the integrated aeroshell that may include, but not limited to:

o Packing into a stowed volume o Launch environment (vibration, ascent depressurization) testing of the packed aeroshell o Cruise environment (Vacuum/thermal cycling exposure) testing o Deployment and inflation o Load tests of deployed aeroshell

- Design and fabricate integration and test fixtures and equipment including instrumentation to obtain test measurements.

- Develop written test plans and procedures.

- Perform a technical analysis of test results and prepare corresponding test documentation and reports.

- Provide onsite technical support for system level tests that are conducted at NASA or other facilities

TECHNICAL TRACK C

GAS GENERATOR INFLATION SYSTEMS DESIGN, MANUFACTURING,

TESTING, AND INTEGRATION WITH INFLATABLE STRUCTURE (IS)

Background:

Studies have shown that, as IAD scale increases, inflation systems utilizing gas generators have greater mass efficiency than compressed gas systems. Gas generators for IAD must be suitable for space environments and produce a gas with minimal water vapor, solid particulates, and by‐ products that may be harmful to IS materials, such as silicone and fluoropolymer components.

The gas temperature at delivery to the IS should be significantly below the operating capability of the liner material. A goal of 200 C is targeted. The volumes to be inflated will range from about 1200 ft3 (34 m3) for a 10m IS to 4000 ft3 (113 m3) for a 20m IS, with IS operating pressures expected to be between 15 to 30 psid (103 to 207 kPa). Inflation will occur exo‐ atmospherically to deploy the aeroshell from its packed condition to its full shape. Rapid inflation is not required, with inflation times expected to be on the order of 10‐60 minutes for the larger‐scale IAD. An initial low flow rate to initiate deployment of the IS from its densely packed condition, followed by a higher uniform flow to fully inflate to the final pressure, is desired. The gas generator system will maintain the IS pressure within a prescribed tolerance while mitigating expected system leak rates. The effort will progress from conceptual design, concept demonstration, fabrication and testing of ground test articles to fabrication and testing of flight articles.

Description of Task Order Content:

C.1 Gas Generator Inflation Systems: The Contractor shall provide design, manufacturing, and testing of gas generator inflation systems including, but not limited to, the following work that may be written as Task Orders (TOs):

- Develop conceptual and detailed designs, and construction methods, of gas generators based on specifications set forth in each TO. The construction design specified in the TO may include, but is not limited to, manufacturing, testing, and integration details and pertinent drawings.

- Fabricate and deliver gas generators and associated gas delivery components.

Gas generators and components will be specified in each TO and may include, but are not limited to, test components, ground test assemblies, or flight unit assemblies.

- Integrate gas generators with components that deliver gas to inflatable aeroshells as specified in each TO. To inflate and control the inflation process, gas generators will need to be integrated with, but not limited to, gas transmission lines, flow control devices, pressure control devices, electronic controls, and instrumentation.

- Develop methods to improve gas generator performance, mass efficiency, reduce discharge temperatures, and avoid by‐products that may potentially harm aeroshell materials. Of particular concern for gas generators: the interaction of by‐products with the silicone and fluoropolymer gas barrier materials in the IS.

- Develop concepts and designs for mechanical interfaces to vehicle structures, subsystem modularity and packaging, installation operations, and non‐ destructive evaluation or inspection.

- Provide mass estimates and actual mass measurements which may include, but are not limited to, estimates of assembly masses, interim mass estimates of components, and final as‐built mass of the assembly.

- Conduct testing for subcomponent, component or system level development tests as specified in the TO.

o This may include, but is not limited to, materials, construction techniques, flow performance, inflation control, interfaces, instrumentation functionality, or environmental testing.

o Develop written test plans and procedures.

o Perform a technical analysis of test results and prepare corresponding test