SOW New Contract - FINAL.pdf

40 Kelvin Shape Memory Alloy (SMA) Development and Alternate Forms Production

Statement of Work

1. BACKGROUND

NASA’s Rover Programs are exploring the use of novel, non-pneumatic, compliant tire technology developed at the NASA Glenn Research Center (GRC) known as the Shape Memory Alloy (SMA) Tire.

This new compliant tire technology has shown significant advantage over previous rigid wheel constructs in terms of durability and traction performance. The SMA tire is attractive to the various rover programs because it has the potential to 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. The revolutionary aspect of the compliant tire technology is the utilization of SMA for the tire material.

However, an SMA with specific thermomechanical characteristics to meet the wide range of mission requirements will need to be developed to enable next-generation SMA compliant tire technology. As such, obtaining SMA wire and alternate forms (springs, fabric, etc.) with extreme temperature and improved fatigue capability are critical to the successful delivery of SMA components that providers can leverage to develop next generation tire technology for the Moon and Mars. Thus, the project requires a contractor/source that can help co-develop and deliver materials and forms, along with complimentary supporting data, over the next 5 years. The Government will furnish specifications for the sequential processing steps that will be explored during the development of the alloys using task orders for each procurement. The ultimate goal of this contract is to bring the readiness level of the SMA to a maturity level sufficient to be utilized for the Artemis missions.

2. SCOPE OF WORK

The scope of work includes processing trials, testing, fabrication, and delivery of SMA wire and alternate forms that can be evaluated for use in the construction of SMA tire technologies for extreme environments. In this case, extreme environment refers to the development of alloys and forms capable of delivering mechanically induced SMA properties, suitable for rover tires, at temperatures down to 40 Kelvin (-233 Celsius). All test data, analyses, processes, and procedures shall be documented as defined by the funding program and will be used to guide the processes to be used for the certification of any commercial off the shelf materials and/or products that result from the effort.

3. BASE WORK AND TASKS

The Government will furnish specifications in a task order for each procurement. The contractor shall 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) Wire and Alternate Forms Fabrication

3.2.1. The contractor shall perform processing trials, fabricate, test, qualify, and deliver SMA wire and/or alternate forms 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 deliver to the Government the specific manufacturing process used in the production of the delivered SMA wire and alternate forms in both electronic pdf via email and hardcopy included with the SMA delivery.

3.3. Element 3 – Testing and Documentation of Wire and Alternate Forms

3.3.1. The contractor shall sample and test wire and/or alternate forms 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 characteristics are achieved. The results of these verification activities shall be furnished upon request by NASA in order to ensure conformity.

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 – Alternate Form Process Development

3.4.1. The contractor shall develop a method to manufacture and produce alternate forms (springs, fabrics, etc.) per task order geometry specifications.

3.4.2. The contractor shall develop methods to perform end and/or edge terminations specific to the alternate form being produced (i.e. loop ends, straight ends, finished edge, etc.) per the guidelines for the geometry specifications outlined in the task order.

3.4.3. If deemed appropriate, the contractor shall perform Testing and Qualification on the end and/or edge 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 wire and/or alternate forms with 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 wire and/or alternate form properties, the contractor will work with NASA to develop these materials, forms, and processes.

NASA program technical authority will have full insight into any processes developed, 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 comply with all applicable Federal, state, and local environmental regulations.

4.3.

4.4. 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.

5.2.1. Engineering drawings shall include revision information, name of design engineer, name of approver, and dates of release/approval.

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

5.3.1. All materials, processes specifications, and process qualification approaches shall be made available to NASA GRC for review in a timely manner (30 days from request).

5.3.2. If greater than 30 days is required, an extension request may be made with the COR and CO with an explanation for the extension request.

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

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

5.6. 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.

5.7. The sampling for material properties (including dynamic properties such as fatigue and fracture) of wire, individual forms or complex structures shall be representative of the material, product form, and state commonly used in non-pneumatic tire architectures using SMAs.

5.9 Prior to production of wire or alternate form 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 Wire and Alternate Forms shall be delivered in segregated lots.

6.2. Each production lot shall contain material produced on a specific machine.

6.3. Each production lot shall contain material produced from a single metal heat.

6.4. A method for tracking each lot to the specified drawing shall be included. This may take the form of product labeling on the lot container, digital tracking of the lot tracing it to the drawing specification, etc.

If multiple heats, machines, or similar are used to produce enough material 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 machine that was used to produce an individual material batch.

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 different 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 wire and/or alternate forms 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

11. PLACE OF PERFORMANCE

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

Fort Wayne Metals Nighthawk 4010 Piper Drive Fort Wayne, IN 46809

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. Records of Inspections and Tests

5.1. 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 end item is fully verified.

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

5.3. Records shall document all actions taken on the component.

6. Contamination Control

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

7. Nonconformance and Problem Reporting and Control

7.1. 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.

7.2. 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.

7.3. 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 nonconformance 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).

7.4. The contractor shall supply a comprehensive list all non-conformances to NASA monthly.

7.5. A reportable problem shall include a problem report including as a minimum but not limited to:

(1) Description of problem.

(2) Analysis of root cause of problem.

(3) Description of corrective action, and

(4) Corrective action follow-up.

8. Control of Nonconforming Product

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

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

9. Calibration

9.1. Only properly calibrated instruments and tools in accordance with NASA or commercial calibration standards and process shall be used to assemble, test, inspect, and verify hardware.

9.2. 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.

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

10.1. 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.

10.2. 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.

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

11. Control of Quality Records

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

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

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

(End of SOW)