SOW Modification Final for posting.pdf

Mars Sample Return (MSR) SMA Springs – Statement of Work

1. BACKGROUND

Recently, NASA’s Rover Programs have been exploring the use of a new, non-pneumatic, compliant tire technology developed at the NASA Glenn Research Center (GRC) known as the Shape Memory Alloy Spring Tire. This new compliant tire technology has shown significant advantage over previous rigid wheel constructs, both in terms of durability and traction performance. The SMA tire is also attractive to the various rover programs because it can be compressed for stowage during transit. This characteristic, which is not possible with rigid wheel constructs, adds additional benefit by reducing the volume needed to package the rover. A complimentary technology to compliant tire technology is the utilization of Shape Memory Alloys (SMA) for the spring material. However an SMA with specific thermomechanical characteristics to meet the fabrication and mission requirements will need to be developed to combine SMAs with compliant tire technology. However, the adoption of this new technology requires the development and utilization of SMA springs with specific thermomechanical characteristics to meet the design requirements pertinent to the specific terrain and environment that will be encountered.As such, obtaining SMA springs that meet project objectives are critical to the successful delivery of SMA tires for this technology application for the mission. Thus, the project requires a contractor/source that can deliver materials with complimentary supporting data and forms for 5 years.

Thus, the project requires a contractor/source that is capable of delivering certified materials and forms for 5 years.The Government will furnish specifications for the SMA spring elements in a task order for each procurement.

2. SCOPE OF WORK

The scope of work includes fabrication, testing, qualification, and delivery of wire and individual SMA spring elements for use in the construction of prototype, engineering models, and flight-qualified tires components. Flight qualification shall include all test data, analyses, processes, procedures, quality assurance audits, and government site visits as defined by the funding program, which is necessary to certify products for spaceflight. The Government will furnish specifications for the SMA springs in a task order for each procurement. The Contractor will develop test procedures to verify the reproducibility of lot tolot spring production. If rim attachment procedures are altered by the Government, the Contractor will modify the SMA spring design and deliver springs in the configuration required as specified in the task order.

3. BASE WORK AND TASKS

The Government will furnish specifications in a task order for each procurement. The contractor shall should respond to requested individual task orders that can include any individual or combination of the types of tasks described in this section.

3.1. Element 1 – Preliminary and Administrative Work

3.1.1 The contractor shall implement a program management system detailed in part 4 of the

SOW.

3.1.2 The contractor shall establish and maintain material and process controls detailed in part 5 of the SOW.

3.1.3 The contractor shall establish and maintain heat and lot control for all material deliveries as detailed in part 6 of the SOW.

3.1.4 The contractor shall submit the Quality Assurance Plan detailed in part 7 of the SOW within 30 days of contract award.

3.2. Element 2 - Shape Memory Alloy (SMA) Spring Fabrication

3.2.1 The contractor shall fabricate, test, qualify and deliver SMA springs with dimensions, tolerances and characteristic properties defined by NASA GRC specifications in each task order.

Dimensions, tolerances, characteristic properties, operating temperature range, non-operating temperature range, and product forms will be defined for each task order to ensure that specific project requirements are met for each stage of the design and build process. The contractor should document and delivery to the Government the specific manufacturing process used in the production of the delivered SMA springs in both electronic pdf via email and hardcopy included with the SMA delivery.

3.3. Element 3 – Testing and Qualification of Springs

3.3.1. The contractor shall sample and test springs from each production lot to verify compliance with the NASA GRC specifications for dimensions, tolerances, and characteristic properties as defined in the task order and to verify consistent and reproducible spring characteristics are achieved.

Tests in both tension and flexure should be conducted through a range of deformations specified by NASA GRC in the task order to ensure that consistent, load deflection response is achieved.

Tests shall be conducted as specified in the task order. The contractor should deliver all data obtained from lot testing conducted in tension and flexure to the Government in both electronic pdf via email and hardcopy for each SMA. delivery. Mechanical testing will be conducted through a range of deformations specified by NASA GRC in each task order to ensure that consistent load-deflection response is achieved.

The contractor will be required to deliver all test data produced to the Government.

3.4. Element 4 – Spring End Formation Process Development

3.4.1. The contractor shall develop a method to perform spring end terminations (i.e. loop ends, straight ends, etc.) per task order geometry specifications.

3.4.2. The contractor shall perform Testing and Qualification on the spring end terminations to verify the processes developed meet the requirements of the task order.

The contractor should perform end-opening and fracture tests to qualify end termination properties and their corresponding reproducibility. Documentation, including all data from the corresponding end-opening and/or fracture tests, should be provided to the Government for each delivery in both electronic pdf via email and hardcopy to verify the lots characteristics and reproducibility.

3.5. Element 5 – Additional Process Design and Development

3.5.1. If the Government determines additional processing routes, manufacturing techniques, or other processes are required to deliver springs of the appropriate properties and geometry, the Contractor shall be responsible for meeting the objectives set forth by the Government.

Additional resources, negotiations of labor rates, schedule and deliverables will be determined on a case-by-case basis.

If it is determined that there is a need for alternate materials or manufacturing processes to achieve the desired spring properties, the contractor will work with NASA to develop these materials and processes.

NASA program technical authority will have full insight into any processes developed or modified or used under this contract.

4. Task Management Requirements

4.1. The contractor shall implement a program management system that enables insight into the technical, cost, risk, and schedule status as well as technical and programmatic control of work performed under the task orders.

4.2. All work performed under this contract shall be in compliance with all applicable Federal, state, and local environmental regulations.

4.3. Task Order Reporting Requirements shall be followed as agreed upon per each task and as listed in the sections 3-9 of this Statement of Work.

5. Materials and Processes

5.1. All materials and processes shall be governed by standards and specifications selected from government, industry, or company specifications and standards.

5.2. All materials and processes shall be identified directly on the appropriate engineering drawing.

5.3. Company materials and processes specifications shall be identified by document number in the acceptance data package.

5.4. All materials, processes specifications, and process qualification approaches shall be made available to NASA GRC for review

5.5. Process specifications shall define process steps at a level of detail that ensures a repeatable/controlled process that produces a consistent and reliable product.

5.6. Process qualification shall be conducted to demonstrate the repeatability of all processes.

5.7. All materials shall be certified as to the composition, properties, and requirements identified by the task order, and a certificate of conformance included in the acceptance data package.

5.8. The sampling for material properties (including dynamic properties such as fatigue and fracture) of individual springs or multi-spring assemblies shall be representative of the material, product form, and state to be used in the final tire design provided by NASA.

5.9. Prior to production of springs for use in flight hardware qualification or flight hardware production a manufacturing readiness review shall be held at the contractor site to review all qualification data.

NASA approval of manufacturing readiness is required prior to production of flight hardware. However, this requirement may not be levied on all task orders where critical flight qualification and flight hardware deliverables are not included.

6. Heat and Lot Control

6.1. Springs shall be delivered in segregated lots.

6.2. Each spring lot shall contain springs produced on a specific winding machine.

6.3. Each spring lot shall contain springs produced from a single metal heat.

If multiple heats, winders, machines, or similar are used in order to produce enough springs to fill an order they must be segregated and delivered in separate packaging so that NASA can maintain traceability back to the metal heat, spool, and winding machine that was used to produce an individual spring.

7. Quality, Safety and Mission Assurance

7.1. Work shall be performed in accordance with the quality system requirements of SAE AS9100, “Quality Management Systems- Requirements for Aviation, Space and Defense Organizations.”

7.2. The contractor shall develop, implement, and maintain a Quality Assurance (QA) Plan, which will address the requirements outlined in Appendix A. This should focus on the specific quality assurance activities related to hardware being procured by GRC. The QA Plan may reference the applicable portions of the contractor’s existing AS9100 Quality Management System, existing quality manual, and procedures.

The QA plan is designed to be a technical planning guide for the technical performance and management of the quality assurance activities specific to this contract.

8. Acceptance Data Package (ADP)

8.1. An ADP shall be submitted for NASA approval which includes contents specified in the task order requirement.

8.1.1. The ADP shall include a certification of conformance to task order requirements.

8.1.1. The ADP shall include all data used to certify conformance to task order requirements.

Note that each task order will include detailed requirements for the Acceptance Data Package. This is to allow tailoring of requirements associated with the criticality of the hardware being delivered. Non-flight hardware may have a difference set of ADP requirements than flight hardware.

9. Deliverables

9.1. Deliverables for the base contract:

9.1.1. A Quality Assurance Plan shall be submitted for NASA approval in accordance with Section 7 of the SOW.

9.2. Deliverables specific to each Task Order:

9.2.1. SMA springs shall be delivered as specified in each task order.

9.2.1. An Acceptance Data Package (ADP) shall be submitted for NASA approval in accordance with Section 8 of the SOW.

10. DELIVERY

10.1. The contractor shall provide all deliverables per Section 3-8 to:

TBD (at task order award) NASA Glenn Research Center, MS TBD 21000 Brookpark Road Cleveland, OH 44135 TBD@nasa.gov

(216) 433-TBD

Ashlee Shaw Contracting Specialist ashlee.b.shaw@nasa.gov

(216) 433-2916

11. PLACE OF PERFORMANCE

11.1. Performance of this work will be at the contractor’s facility.

12. PERIOD OF PERFORMANCE

12.1. The period of performance of this effort shall begin at task order award and continue for 5 years following task order award.

Appendix A Quality Assurance Plan Content

1. Configuration Management (CM) and Verification

1.1. All documents, drawings, and revisions, which define and verify the system, shall be kept under configuration control.

1.2. The contractor's CM system shall be capable of assuring that as-built hardware conforms to the design documentation.

1.3. Inspection records shall indicate the revision level with which the item has been fabricated, inspected, and/or tested.

2. Control of Fabrication Activities

2.1. A fabrication flow process shall be developed and implemented that covers operations from start of fabrication to end item completion.

2.2. Inspection and test points and all special processes to be used shall be included in the fabrication flow.

2.3. Controls shall ensure that only conforming components are released and used during fabrication.

3. Inspection and Test Procedures

3 .1. Inspection and Test Procedures shall be written for all operations.

3 .2. Written assurances that these procedures were followed shall be provided in records (such as logbooks, or other project-appropriate documentation methods).

3.3. Any deviations from these procedures shall be documented.

3.4. Each operation shall have a responsible individual for its accomplishment.

3.5. The responsible individual's name shall be recorded in the records.

3.6. Procedures shall include, as applicable, the revision level of the document, the nomenclature of the article, instructions for qualified personnel to perform the work, characteristics to be inspected or tested, accept/reject criteria, and special considerations regarding handling, measuring, testing, equipment, standards, safety, and environment.

3.7. The contractor's QA organization shall verify that proper inspection and testing criteria are included in the procedures during the QA review of processes, procedures, and specifications.

NASA reserves the option to require NASA approval. This would be specified on the task order.

3.8. Prior to any testing or inspection QA shall assure that all applicable procedures are available, test/ inspection equipment is calibrated and properly configured, and the facility is properly configured.

3.9. Procedures shall require the recording of equipment identification and calibration due dates for all calibrated instruments used.

3.10. The records of this activity shall be kept in sufficient detail to verify and evaluate the status of all articles and materials tested/ inspected.

4. Training for Personnel

4.1. The contractor shall establish and maintain documented procedures for identifying training needs, and provide for the training of all personnel performing activities affecting quality.

4.2. Personnel performing specific assigned tasks shall be qualified on the basis of appropriate education, training and/or experience, as required.

4.3. The contractor shall specify in the QA plan the training needs for the work performed.

4.4. Appropriate records of training shall be maintained.

5. Bonded Storage

5 .1. The contractor shall maintain a controlled bonded storage area, which is capable of storing flight material, parts, and assemblies.

5.2. The level and type of environmental control shall be defined in the task order and will be based on the specifics of the flight material, parts, and assemblies bein~ stored.

5.3. The environmental controls shall appropriately protect the flight items from excessive temperatures and humidity, and from contamination as define in the task order.

5.4. The area shall have controlled access applicable to the type of items being held, with a documentation system adequate to identify and track the flow of parts in and out of bonded storage.

5.5. Bonded storage shall be capable of segregating materials, assemblies, qualified components, and nonconforming components.

5.6. Traceability by Heat Lot, Spring Lot, serial numbers, and lot date code shall be maintained for parts and components in controlled storage.

6. Records of Inspections and Tests

6.1. Records shall be maintained for a minimum of 5 years for all inspections and tests as evidence that all operations have been performed, objectives have been met, and the enditem is fully verified.

6.2. Records (such as logbooks, or other project-appropriate documentation methods) shall be kept for each component and assembly.

6.3. Records shall document all actions taken on the component

7. Contamination Control

The contractor shall define contamination control requirements appropriate for work under this contract, including the contamination control of the manufacturing processes, and assure compliance.

8. Nonconformance and Problem Reporting and Control

8.1. The contractor shall implement a closed-loop system for identifying, documenting, controlling, and correcting non-conformances in compliance with SAE AS9100, Control of Nonconforming Product. The contractor shall document this system and its use, including the involvement of the contractor's quality department.

8.2. The contractor shall begin reporting any non-conformances that occur beginning at the developmental phase and continuing through acceptance of prototype, engineering model, and final flight hardware.

NASA will review and approve all "use-as-is" and non-standard repair dispositions.

8.3. The contractor shall inform NASA of all reportable problems and actions that require NASA approval within 48 hours of the discovery of the occurrence.

A reportable problem is any noncoriformance which is, or is suspected of being, a failure, an unsatisfactory condition, an unexplained anomaly, or an overstress occurring during or subsequent to production acceptance testing or qualification testing (i.e., after manufacturing or development).

8.4. The contractor shall supply a comprehensive list all non-conformances to NASA on a monthly basis.

8.5. A reportable problem shall include a problem report including as a minimum:

(1) Description of problem.

2) Analysis of root cause of problem.

(3) Description of corrective action, and

(4) Corrective action follow-up.

9. Control of Nonconforming Product

9 .1. Any nonconforming item shall be identified and segregated to the extent possible.

9.2. The nonconformance and any immediate action(s) taken shall be documented.

10. Calibration

10.1. Only properly calibrated instruments and tools in accordance with NPD 8730.1 shall be used to assemble, test, inspect, and verify flight hardware. The complete version of NPD

8730.1 can be viewed at https://nodis3.gsfc.nasa.gov/npg img/N PD 8730 00 lC IN PD 8730 0OlC main.pdf

10.2. Individual records of measurement standards and equipment shall be maintained. Records include identification of standard use, identification of equipment calibrated, identification of calibration procedure used, calibration time interval to next calibration, results of calibration, and individuals performing the calibration.

11. Handling, Preservation, Marking, Packaging, Packing, and Transportation

11.1. The contractor shall develop and implement procedures for handling, preservation, marking, packaging, packing, and transportation to properly protect and identify all flight systems and ground support equipment during buildup, handling, storage, testing, shipping, and turnover at integration.

11.2. The contractor's QA organization shall verify that the articles and materials have been prepared and packaged in accordance with applicable procedures and requirements and have been properly identified and marked.

11.3. All accompanying documents shall have been properly identified as to inspection status with the appropriate inspection stamps.

12. Control of Quality Records

12.1 . The contractor shall establish and maintain documented procedures for identification, collection, indexing, access, filing, storage, maintenance, and disposition of quality records.

12.2. The quality records shall be maintained to demonstrate conformance to specified requirements and the effective operation of the quality system.

12.3. Pertinent quality records from the subcontractor shall be an element of these data.

(End of SOW)