SOW H4WM04 FTS second phase v4.pdf

Statement of Work

Fatigue Testing Load Frames – Second Phase

H4WM04

1.0 Scope - This statement of work details the requirements for furnishing, shipping, installing, assembling, and verification/calibration testing of commercially available items. The testing hardware shall be utilized to apply cyclical loading for fatigue, monotonic tensile and compressive loading, as well as constant tensile forces for creep testing. This testing equipment will validate material capabilities of polymers and metals constructed using additive manufacturing (AM), along with other standard quality control testing of stock materials that shall be tested using tension, compression, shear, creep, and fatigue. It will also be used to test many other metallic and polymeric test samples from various OC-ALC groups to verify that the material is within its specified condition or capability range. Technical requirements for the Fatigue Testing System (FTS) and its accessories are specified below. The contractor shall provide all labor, tools, equipment, materials, parts, personal protective equipment (PPE), transportation and any other incidentals for travel to

Tinker AFB, OK. Offloading and placement of the FTS will be provided by Tinker AFB personnel at the guidance of the contractor’s technical personnel. The contractor shall provide basic operational training for all supplied equipment/software to Tinker AFB personnel following full system commissioning by the contactor and acceptance by government personnel.

2.0 Requirements and Specifications

• 2.1 This equipment shall be procured from a single commercial manufacturer’s current production year model line. All components, mechanisms and assemblies furnished with the FTS shall comply with applicable requirements of OSHA. It shall be new, unused, and not comprised from any refurbished parts or assemblies as follows:

2.2 Two (2) each 250 kN (56.2 kip) Servohydraulic Fatigue Load Frames:

• Load Cell Capacity: 250 kilo-Newtons (kN) with self-identification capability, including mounting hardware and tools.

• Actuator piston rod with extended life hard-face wear coating.

• Extended height/length columns with Tie Bar.

• Hydraulic powered crosshead movement.

• Hydraulic actuator and powered grip controls mounted to front of load frame and include a remote control/pendant with cradle mount.

• Actuator Power Source: Hydraulic, Anti-Rotation.

• Must include multipurpose dual hydraulic servo valves for high cycle fatigue testing.

• Two, Hydraulic collet grips, 250 kN (55 kip) capacity

▪ Hydraulic action with maximum grip pressure of 45 MPa (6500 psi).

▪ Temperature range of -40 to 65°C.

▪ Ported for optional water cooling.

▪ Grip collets capable of accepting 0.5-inch shank diameter specimens.

▪ Attachment kit to ensure compatibility of grips to actuator and load cell.

• Three, 1-inch Axial extensometers for compression, tension, fatigue, creep testing. Must include both knife edges and three-point attachments for both flat and round specimens, capable of strain measurements from +50% to -10%, including elastic attachment kit, with all necessary cables, connectors, and attachments, with a rigid storage case.

• Three, 2-inch Axial extensometers for compression, tension, fatigue, creep testing. Must include both knife edges and three-point attachments for both flat and round specimens, capable of strain measurements from +50% to -10%, including elastic attachment kit, with all necessary cables, connectors, and attachments, with a rigid storage case.

• Crack Opening Displacement (COD) gauge for performing tests to determine KIC, JIC, and crack growth rates. Must be capable of testing a variety of specimens including compact tension, WOL, round compact tension, C-shaped, bend, and other common specimens or panels. Gauge length must be 0.2 in. and capable of traveling +0.100/-0.050 in. within a temperature range of -150° to

+300°F, with all necessary cable, connectors, and attachments. A rigid storage case shall be included.

• Desktop computer for each test frame with Windows 10 operating system including all requirements listed in section 2.6.

• Test monitoring data hub with necessary hardware, software, and cables, enabling a remote monitoring computer to see real-time events and performance statistics on a local network using

Ethernet cables. It shall enable customizable desktop PC alerts and notifications on a separate PC that will be at a desk that is between 50 to 150 feet distance from the FTS location.

• Load frame and accessories delivery, setup, testing and commissioning, with on-site calibration of axial displacement, axial force, and displacement/strain of each extensometer.

2.3 One 100 kN (22,450 lb-f) Hydraulic Load Frames:

• Load Cell Capacity: 100 kN with self-identification capability, including mounting hardware and tools.

• Extended height/length column with Tie Bar.

• Actuator piston rod with extended life hard-face wear coating.

• Hydraulic powered crosshead movement.

• Hydraulic actuator and powered grip controls mounted to front of load frame and include a remote control/pendant with cradle mount.

• Actuator Power Source: Hydraulic, Anti-Rotation.

• Must include multipurpose dual hydraulic servo valves for high cycle fatigue testing.

• High-temperature hydraulic grips specifically designed for high-temperature, low-cycle fatigue.

▪ Dynamic force rating at 700°C: 68 kN (15 kip)

▪ Dynamic force rating at 1000°C: 8.9 kN (2 kip)

▪ Hydraulic actuation with water cooling to include all necessary hoses and connections.

▪ Attachment kit to ensure compatibility of grips to actuator and load cell.

▪ Buttonhead and threaded grip adapters for 0.5 inch specimens constructed of superalloy to minimize thermal gradients with specimen.

• Hydraulic collet grips, 100 kN (22 kip) capacity

▪ Hydraulic action with maximum grip pressure of 45 MPa (6500 psi).

▪ Temperature range of -40 to 65°C.

▪ Ported for optional water cooling.

▪ Grip collets capable of accepting 0.5-inch shank diameter specimens.

▪ Attachment kit to ensure compatibility of grips to actuator and load cell.

▪ Self-contained hydraulic grip supply/controller with pressure range of 1,500-

10,000 psi

• Desktop computer with Windows 10 operating system including all requirements listed in section

2.6.

• Test monitoring data hub with necessary hardware, software, and cables, enabling a remote monitoring computer to see real-time events and performance statistics on a local network using

Ethernet cables. It shall enable customizable desktop PC alerts and notifications on a separate PC that will be at a desk that is at least 50 feet distance from the FTS location.

• Load frame and accessories delivery, setup, testing and commissioning, with on-site calibration of axial displacement, axial force (from 0-25 kN, and 0-100 kN), and displacement/strain of each extensometer.

2.4 Alignment System Package

The Alignment System Package shall be capable of efficient load frame alignment using turnkey software. All necessary data acquisition and conditioning functionality shall be included to permit regular adjustments. The system shall be capable of achieving the alignment required per standard

ASTM E1012.

• Compliant with Windows 10 and contains all necessary cables and connections.

• Acquires, analyzes, and displays bending strains to permit alignment and bending strain verification.

• Metrology certification must be included.

• Software should be intuitive and include a guide to assist users in performing alignment. The software shall be capable of generating a report to certify system alignment when procedure is finished.

• Software shall be preinstalled on each delivered computer and available on a CD for installation on other fatigue system computers. Software license key must be included.

• Strain-gauged specimen of 0.5 in. diameter to be used to correct both concentric and angular test system misalignment. Specimen shall have 12 strain gauges which must communicate with the alignment software.

2.5 Direct Current Potential Drop (DCPD) System

Supply a DCPD system that shall be used to measure the crack length via a voltage which is correlated to the crack length. The DCPD system shall correct for fluctuations in current or specimen conductivity by measuring a reference specimen. It shall be capable of operation in high-temperature and other challenging environments where standard crack opening gauges are impractical.

• Power cord for North America (100-120 VAC)

• Software capable of making crack growth measurements with a test specimen and reference specimen. Must integrate with load frame controller software.

• All associated cables required for testing and communication with load frame and controller.

2.6 Computers Hardware and Software Requirements:

• Each load frame specified within this SOW shall be supplied with desktop computer with a

Windows 10 operating system allowing full operation of, monitoring progress, programing tests, modifications of test programs, recording of test data, analyses of both single sample test data and batches of samples data, run, pause and stop tests, and export test data within supplied reporting templates and modifiable report formats.

• The load frame operating/controlling software will enable sinusoidal, square, and pyramidal wave forms for either load (kN/second) or displacement (inches/second) for cyclic testing, as well as both load-rate (kN/second) or piston displacement-rate (inches/second) control for static testing.

• The FTS will be non-networked (have no internet connections) and all installed software must be fully functional off-line. Software upgrades or patches must be delivered via DVD or other approved digital storage device for a period of one (1) year after final government acceptance.

• Include both hardware/software for a Data/Statistics transfer hub that allows remote monitoring of live test data/statistics via a separate computer workstation connected by an Ethernet cable

(local closed-loop network via contractor supplied LAN cables) no further than 150 feet distance from the FTS.

• Each load frame’s computer shall have the contractor’s complete version of their software suite installed and operable on each of the supplied PC workstations, further specified below.

The following minimum Computer hardware and Software capabilities/functions shall be required

(items may be exact or equivalent to):

2.6.1 Hardware:

▪ Supply three (3) each Workstation-grade quad-core (minimum) Computers –Desktop

CPU’s

▪ Each CPU shall have the following:

▪ 64-bit Windows operating system.

▪ Minimum of two (2) internal hard drives (500 GB minimum); either HDD or SDD hard drive type for data storage; SDD hard drive type mandatory for software and operating system applications.

▪ Minimum 16GB RAM

▪ One (1) (minimum) DVD+/-RW compatible internal optical drive

▪ Two (2) (minimum) Gigabit LAN Ethernet ports. A LAN port built into the motherboard counts as one.

▪ Two (2) twenty-three inch (23”) minimum LCD Monitors, with all necessary cables.

▪ One (1) set of Wireless Keyboard and Mouse (Bluetooth).

2.6.2 Software:

▪ The software shall be installed on the workstations designated software hard drive (SDD).

▪ Windows 10 Pro-based Operating System

▪ The FTS specific software that shall control/analyze each test frame, be supplied from a single manufacturer, and shall be able to perform:

o Activate options to Start, Pause, Stop, and Abort for all test programs, and perform analysis of test results from both static and dynamic testing.

o Allow test programming, and test modifications to parameters, and test setup for both low and high cycle fatigue testing.

o Creation of unique test programs.

o Perform Fracture Toughness testing (J1c) and analyses of those results.

o Build a library of test results of fatigue crack growth testing and comparison reporting.

o Provide error/warnings and alerts, generate data with reports, and enable its analyses, have automatic pre-formatted and editable format reporting.

o Allow both raw test data and reports to be downloaded via USB ports, and for conversion of repots to PFD formats via Adobe Acrobat.

o Each computer shall include Microsoft Office and Adobe Acrobat Pro, non-networked or offline only version.

o Turn on/off hydraulic power supply, and the hydraulic manifolds.

o Shall enable in-depth analysis of test data in both graphical and tabular formats.

o Shall display real-time performance statistics and event data that can also be remotely monitored from active dynamic tests via the data transfer hub.

2.7 Other Load Frame Requirements and Accessories:

• All necessary tools, kits, cables, hoses, adapters, plugs, and other equipment required to use/operate the FTS, and install/use/uninstall any of its accessories, shall be included.

• The data acquisition rate for each load frame shall have an acquisition rate no less than 2,000 Hz.

• The base of each load frame shall be equipped with vibration damping pads to ensure adjacent hardware will not be affected during operation of the fatigue testing frames.

• Each of the extended column load frames shall be further stiffened/strengthened by adding a column tie bar.

2.8 Construction – All parts and materials used in the construction of the FTS shall be new. The quality of construction shall be provided to meet the strength, rigidity and wear resistance characteristics necessary to meet international standards, including: ASTM D3039, ASTM D2344, ASTM D790, ASTM D3518, ASTM D5023, ASTM D5024, ASTM D5026, ASTM D5418, ASTM D5992, ASTM D6272, ASTM D7028, ASTM E21, ASTM E290, ASTM E517, ASTM E646, ASTM E8-E8M, ASTM

E9, ISO 10113, ISO 14125, ISO 6892-1, ISO 6892-2, ISO 7438, ISO 14129, ISO 527-5, ISO 6721-4, ISO

6721-12, EN 2561, EN 2562, EN 2597, EN 2746, and EN 6031 for static and dynamic testing for accuracy, performance, and safety. All parts and mechanisms requiring adjustment, replacement or servicing shall be readily accessible. The FTS and its testing accessories shall be complete so that when installed and connected to the proper utilities it shall be ready for use.

2.9 Maintenance Manuals & Software – Test procedures and instructions/manuals shall be provided for identification of, location of, and repair method for any mechanical, electrical, or software failures. Parts lists/drawings, circuit diagrams and electrical/electronic schematics shall be provided. The contractor shall provide/deliver all (offline) software updates or patches when they become available during the twelve (12) month warranty period.

2.10 Lubrication Maintenance – All parts of the FTS requiring periodic and annual maintenance shall be specified in the provided documentation/manuals to ensure maximum operational uptime and longevity of the FTS system and its accessories. Hardware requiring periodic lubrication as specified in manuals shall also have the necessary equipment (tools) with which to provide said lubrication. Systems using recirculated oil, or hydraulic fluid, shall be equipped with a replaceable or washable filters.

2.11 Sliding Contact Surfaces – All moving contact surface components of the FTS requiring lubrication or maintenance shall be specified. All contact/moving surfaces shall be constructed to withstand the applicable applied loads without wear or damage. All sliding surfaces that are subject to wear shall have provisions for lubrication, provide necessary lubricants, and/or have replaceable parts or contact surfaces available.

2.12 Safety and Health –The contractor shall be responsible to provide safety devices or equipment for the FTS in accordance with the Safety and Health sections 2.11.1-2.12. The equipment provided for the FTS hardware/software shall help prevent potential safety hazards to operators, such as pinches, crushing, or projectiles. Those devices shall include A) Emergency shut off buttons located at the test frame and within the software B) Slowed actuator movement software settings during test setup or sample placement to prevent pinching/crashing. Safety devices shall not interfere with the operation of the FTS or its test equipment. The safety devices shall be removable to facilitate inspections, preventive or remedial maintenance, and during replacement of wearing part(s) as needed.

2.12.1 Mercury Restriction – No mercury components shall be added to the FTS. Trace amounts of mercury naturally occurring are acceptable as long as no additional mercury is added.

2.12.2 Asbestos Restriction – Asbestos and materials containing asbestos shall not be used on or in the FTS and are strictly forbidden.

2.12.3 Lead Restriction – No lead components shall be added to the FTS. Trace amounts of lead naturally occurring are acceptable as long as no additional lead is added.

2.12.4 Ozone Depleting Substances - All class 1 ozone depleting substances (ODSs) are strictly forbidden.

2.13 Environmental Protection – Under the operating, service, transportation and storage conditions described herein, the FTS will not emit materials or radiation hazardous to the operator or ecological system as prohibited by Federal, State or Local statutes in effect at the time of installation.

2.14 Affirmative Procurement Determination - Green/Affirmative Procurement has been determined not to be applicable to this procurement.

3.0 Peripheral Devices

3.1 Un-Interrupted Power Supplies (UPS) – An industry standard UPS shall be supplied to power each of the supplied critical electronic software (computers, monitors, and test frame controllers), and/or hardware, protecting it and the test data, and enabling the safe shutdown of the FTS system if prolonged outage occurs. The UPS included with each hydraulic test frame shall have a minimum of 1.5 kilovolt amps (KVA) power rating, and supply a minimum of 115 volts, with 50/60 Hz frequency, include a power cord, and shall be capable of 15 minutes (minimum) of operation time for the specified FTS 100kN load frame with each computer/monitor/controller, and the 250kN load frames with each computer/monitor/controller. The UPS units shall be easily maintainable and have commercially available replacement batteries.

3.2 Tool Boxes and Storage Containers – Each load frame, including its associated testing accessories, shall have the necessary tools supplied to perform basic preventive and remedial maintenance on the FTS test frames and accessories. Those tools shall be contained within a hard-case tool kit or tool box that contains those necessary tools. Soft lined (or padded) hard-shell storage containers shall be provided for each axial extensometers. All matched sets of sample grips and 3- or 4- point bend test rollers shall have their own hard-shell storage container.

4.0 Additional Equipment

4.1 Equipment/Machine/Accessory Manuals – Manuals shall be provided for each piece of the

FTS system and its accessories. Manuals shall be delivered on electronic storage media, and in print.

This technical data will include items such as operating manuals (with ranges or limits of operation), maintenance manuals, parts catalogs, parts lists, wiring schematics (if applicable), and factory calibration test results. All manuals shall be written in the English language. The equipment

(hardware) technical data and installation/site preparation manuals (PDF format is acceptable) will be delivered no later than 30 days after contract award to ensure that adequate shop floor planning and modifications may be completed prior to FTS delivery. Any necessary facility modifications for the FTS may require three (3) months advanced notice for government employees to perform such construction/modifications.

4.2 Electrical Equipment – The electrical systems of the FTS, and all electrical components thereof, will work with standard electrical voltages available at Tinker AFB, within the following ranges: 115 VAC +/- 10%, or 208 VAC+/- 10%, or 480 VAC at 60 Hz. Individual components’ specific power requirements (Volts, Hertz, Amps) of the FTS shall be delivered to Tinker AFB no later than 30 days after contract award. Any Amperage requirements above 20 amps specified for the FTS equipment shall be documented in the technical manuals and communicated to Tinker AFB.

Electrical plugs or connections shall be standard electrical receptacles meeting current US and

Oklahoma State codes.

4.3 FTS Equipment Nameplates / ID Tags – A corrosion resistant ID Tag or ‘Nameplate’ identifying each fatigue load frame shall be securely attached to each frame and be easily readable.

The nameplate should contain the information listed below. The captions may be shortened or abbreviated, provided the entry for each is clear to its identity:

Manufacturer’s Name

Manufacturer’s Model Designation

Manufacturer’s Serial Number

Power Input (volts, total full load amps, phase, frequency)

Date of Manufacture

5.0 Contract Monitor, Contract Officer Representative (COR), or Government Representative

Provisions (Subject Matter Experts or Lab Personnel)

5.1 Responsibility for Inspection – Government representatives, with the COR, shall conduct inspections of the FTS supplied equipment, software, and accessories upon delivery to the destination site and/or following contractor commissioning. The contractor is responsible for establishing their system commissioning performance tests and inspections to ensure all the equipment is fully functional, and supplying a written report of those test results to the government representatives and COR. The Government reserves the right to perform any of the inspections set forth in the specification when such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

5.2 Quality Conformance Inspection – Quality conformance inspection shall be applied to each item prior to being offered for final acceptance under the contract. Preliminary quality conformance inspections performed prior to shipment will be conducted again at the receiving facility at Tinker

AFB. A quality conformance inspection shall also be conducted at the installation site, after installation and commissioning is completed, ensuring calibrations have been re-tested and verified to be accurate under supervision of government representatives and/or SME’s. The calibration data obtained in both the off-site factory calibrations, and the on-site calibrations, and final quality conformance checks, shall be furnished with the machines in a standard certificate format. Failure of any item to pass any examination or test shall be cause for rejection. The FTS, and its associated equipment, within this purchase will remain the property of the contractor until all items of this quality conformance inspection have been passed and accepted by the government representatives.

5.3 Examination – Prior to acceptance, the FTS and all associated equipment shall be examined by representatives of the government (COR and SME’s) for compliance with design, construction, materials, components, electrical equipment, and workmanship requirements as specified within this SOW.

5.4 Tests & Calibrations – The contractor shall demonstrate that all fatigue load frames, hardware, software, measurement accessories, and powered actuation devices perform as required herein, using accepted industry standards for testing and calibration, provided these tests demonstrate all performance requirements stated in this purchase description. Failure of any test to demonstrate that the FTS hardware, software, and its accessories, performance capabilities meet the minimum requirements as specified herein, or to meet the contractor’s own technical manual specifications, shall be cause for rejection.

6.0 Warranty – The contractor’s standard twelve (12) month warranty shall be provided for all FTS components within this purchase. The warranty period will begin once installation, inspection, on-site calibration, commissioning, testing, and government acceptance has been approved by the COR and representatives of the government. Warranty claim shall include repair or replacement of component, calibration and/or alignment of system (if required), and cost of a field service engineer visit at no additional financial cost to the Air Force.

7.0 Training – The contractor will provide on-site basic training for the FTS, each of the individual load frames, their accessories, and software, to the Air Force employees (expected users). It will include information on using the associated computer software, load frame testing frames and their accessories

(hardware), the hydraulic power supply unit (HPU), and shall cover all basic preventive and remedial equipment maintenance, as well as their best practices for the equipment. The contractor shall provide one advanced user training course during the on-site commissioning and training period, following completion of the basic training, for the expected system users. The advanced training shall be between

2 to 4 hours in duration, and shall cover training topics such as:

A) Test software procedure creation

B) Basic test setup with PID tuning, C) General concepts with navigation and test results with data acquisition

D) Test frame safety with loading samples and running tests and reviewing results

8.0 Software Support – Vendor will supply all software updates and/or patches free of charge for one

(1) year after the FTS system commissioning and government acceptance, and it shall be delivered via

DVD or other portable storage media (non-network). This software support will include one (1) year of telephone support associated with all functions of the operation of the FTS and its accessories. All updates/patches must be delivered offline on DVD or similar media.

9.0 Shipping – The contractor shall include all costs associated with shipping or transport of all items associated with this purchase description to the final destination of Tinker AFB, OK. The contractor shall provide the shipping number and tracking information to Tinker AFB. Upon delivery, Tinker AFB personnel will offload the equipment to a staging area until representatives of the contractor can be on site for final installation. Any special accommodations will be noted by the contractor prior to receipt of equipment. Staging of equipment will not exceed 14 calendar days upon receipt of equipment, unless negotiated and agreed upon by the contractor and contracting officer if changes from the original contract are deemed necessary.

10.0 Installation – Installation shall be completed by the contractor following equipment delivery to the staging area as outlined in paragraph 9.0. Contractor shall specify all installation and facility requirements prior to delivery. These specifications shall include the special use of material handling equipment (i.e. forklift/crane) required to stand equipment and move to final installation location. The contractor is responsible for making all power hookups (electric, hydraulic, etc.) necessary for the installation using the appropriate tools and equipment supplied by the contractor. No modifications shall be made to the facility or infrastructure without prior notification and approval from the Contract

Officer (CO) and/or government representatives (subject matter experts or lab personnel). The Air Force shall not be liable for any damages to equipment during installation, and any damages shall be remediated with new parts at no cost to the Government.

11.0 Commissioning – Within two months of the award date, the contractor shall provide a schedule to the Government POC (engineer/customer), Contracting Officer, and Contract Specialist with the following milestones:

A) Origin Inspection

B) Delivery

C) Install

D) Testing and Calibration

E) Training

The contractor shall notify the government representative of any possible schedule delays.