SOW Specification Sheet.pdf

High Temperature Flexure Test Stand Furnace Specification.

An inert gas furnace for high temperature mechanical testing of carbon and metal-carbide based composites is required. The furnace must fit inside a MTS Criterion Model C45.504 Wide test stand. Bidders shall provide a quote to include conceptual design drawings, space required for secondary cabinets, utility requirements, and a delivery and installation schedule for a system that meets the specifications provided below with separate prices for optional item groups.

General Furnace Specification

1. The furnace chamber, including mounting hardware and loading rams needs to fit within the working space of the MTS Criterion Model C45.504 Wide test stand. The specified dimension for the working space is 39.37-inches maximum width and 59.81-inches maximum height. The maximum load on the system in use will be 50 kN. The quote should assume the use of the MTS Model LPS.504 50 kN load cell with a M27 x 2 mm mating thread and the option to add a tandem load cell MTS Model LPS.253 2.5 kN load cell with an M12 x 1.25 mating thread as well as the required M27 to M12 piggyback adapter. The exact model of tandem cell has not yet been decided but will not exceed 5 kN

2. The furnace will mount securely to the bottom of the provided MTS Criterion Model C45.504 Wide test stand.

3. The furnace chamber shall operate at pressures from vacuum to a slight overpressure, of inert gas, between 0.3 psig to 2 psig.

4. The furnace shall allow mechanical testing from room temperature to 1700°C in an inert atmosphere. (optional specifications listed)

5. When the front door of the furnace chamber is open the interior of the hot zone shall be fully accessible for installation of graphite loading rams, test fixturing and test specimens.

6. The furnace chamber shall have a secondary door to allow access to install instrumentation such as extensometers behind the hot zone. The door shall be located on the rear or side of the chamber. This secondary door with rear access shall be at least 17-inches on the diagonal and at least 12-inches in the minimum dimension. The door shall be equipped with manual door clamps.

7. The furnace chamber shall have sufficient interior space to allow mounting of an extensometer that will reach the center of the hot zone. With enough extra room to fully withdraw the extensometer from the furnace chamber without removing the hot zone. For purpose of the bid assume a Epsilon Model 3549 extension rod extensometer with arms long enough to reach the center of the hot zone. (optional specifications listed)

8. The furnace chamber will be equipped with a manual vacuum pressure gage in addition to any electronic pressure gages, 30 psig × 30 inches Hg.

9. The furnace chamber shall be equipped with a manual valve for equalization of the pressure between the chamber interior and the room, to only be used when the furnace is fully cooled.

10. The furnace chamber shall be equipped with centered front and rear windows with a clear view through the hot zone, of at least 2-inches in diameter. The window ports shall have inert gas purge.

The windows will be made of high purity quartz (amorphous silica). (optional specifications listed)

11. The furnace chamber shall be equipped with a port with a window at least 1.5 inches in diameter with a clear view of the center of the hot zone for mounting the pyrometer. This window will not be on the center of the door or rear of the chamber and the window port will need to be angled to align with the center of the furnace. The window will be made of high purity quartz (amorphous silica). (optional specifications listed)

12. No spot on the exterior surface of the chamber shall exceed 70°C, handles and knobs shall not exceed 55°C while the furnace is at maximum temperature or after 1 hour at 1700°C. (optional specifications listed)

13. The furnace chamber and hot zone will allow for 6-inches of ram travel when installed.

Hot Zone

14. The hot zone shall be of split design. It shall have a free space between the inside surface of the heating elements of at least 11-inch diameter by at least 12 inches tall. A rectangle hot zone can also be used if the free interior space is at least 11 inches wide by 11 inches deep by 12-inches tall.

15. The hot zone shall be able to achieve a temperature of 1700°C for testing, with a hold duration of 1 hour or greater, with a maximum temperature of 1750°C. The hot zone shall have a temperature uniformity over a central work volume of 10 inches diameter by 8 inches tall using an argon atmosphere from 800°C to 1650°C of ±10°C. (optional specifications listed)

16. The hot zone shall be equipped with two replaceable graphite rods, 3-inches in diameter, that attach to the top and bottom water-cooled steel push rods and will meet 3-inches below the furnace center with the crosshead at its minimum lowered position and have 6-inches of clearance centered in the hot zone when the crosshead is at its maximum raised position. (optional specifications listed)

17. The hot zone shall allow viewing of the center of the chamber with a view through the front and rear center exterior ports of 1/2 inch wide by 2 inches tall. (optional specifications listed)

18. The hot zone shall allow viewing of the center of the hot zone from the pyrometer widow with a hole at least 5/8th inch in diameter. (optional specifications listed)

19. The hot zone design shall allow access for an extension rod extensometer from the rear of the hot zone. This may use the center rear opening in the hot zone. (optional specifications listed)

Vacuum and Process Gas System

20. The inert gas vacuum system will allow for the evacuation and backfill of the chamber prior to heating as well as provide gas flow to maintain a positive chamber pressure during the heating run.

21. The chamber shall be fitted with a pressure relief valve set to the maximum chamber operating pressure.

22. All gas fittings and gas tubing will be copper, brass or stainless steel.

23. The gas system shall be equipped with a gas solenoid controlled inlet valve, electronic mass flow controller for low flow control, and a high and low rate fill rate switch.

24. The pressure system shall be equipped with dual capacitance diaphragm gauges for accurate pressure measurement from 0.1 to 10 mmHg and from 10 to 1000 mmHg.

25. The high flow rate shall be enough to backfill the chamber to atmospheric pressure in 20 minutes or less.

26. The gas and vacuum system shall be equipped with an electronic display panel or status lights to indicate the current mode of operation and pressure.

27. The system shall include mechanical vacuum pump capable of pulling the chamber down to less than 0.10 mmHg in 20 minutes or less, when the chamber is clean and dry, and to achieve a minimum pressure at or below 0.01 mmHg.

28. The system shall include a remote controlled roughing valve.

29. The system shall include a leak checking port with manual valve.

30. The main vacuum line shall be equipped with an inlet filter to protect the mechanical pump from graphite particles.

31. The evacuation-backfill process and setting operational gas flow rates can be under manual or automatic control.

32. The furnace chamber shall be supplied with an inert gas distribution system.

Power Supply:

33. The power supply shall have sufficient power to heat the hot zone to 1700°C within 60 minutes and have the hot zone reach a maximum temperature of 1750°C within 70 minutes. (optional specifications listed)

34. The power control system shall display the voltage and amperage for each heating circuit as well as the on-off status of the power supply and water flow.

35. The power supply is limited to a single 100 amp, 3-phase 480 volt circuit for heating the furnace.

Additional circuits of up to 50 amps, 3-phase 480 volt are available for powering the control system and vacuum pump.

36. The power supply shall be equipped with a switch to shut off the power if insufficient water flow is detected and to switch from the cooling tower loop to the emergency water circuit for safe cool down.

Furnace Temperature Control and Data Logging

37. The furnace shall be equipped with two tungsten coated, molybdenum sheathed type "C" thermocouples (TC). One thermocouple is used for furnace temperature control up to 1700°C and can be retracted while heating. The other TC is an over-temperature senser and is coupled with a high temperature limit controller. If an overtemperature condition is sensed the controller will shut off power to the hot zone.

38. The furnace shall be equipped with a 2-color optical pyrometer, with a temperature range of, at a minimum, 1000° -2400°C. The pyrometer is used for furnace temperature control above 1600°C.

(optional specifications listed)

39. The pyrometer will be mounted to the furnace with an adjustable mount so that the exact temperature reading spot can be adjusted a small amount. (optional specifications listed)

40. The system shall be equipped with output signals, ±10 volt analog, for the control thermocouple and control pyrometer temperatures, and temperature setpoint for use with MTS control system.

41. All controls, controllers, outputs, and meters are located on the front of the control cabinet or in a location to promote safe operation.

42. System shall include an emergency STOP button to shut down the furnace power completely in case of emergency.

Cooling System

43. The system will include water inlet manifold and outlet manifold with a single inlet and outlet line connected to the in-house water tower cooling loop and city water (emergency water).

44. The system shall provide valves for both the inlet and outlet of both water systems. This will require at least four valves, tower loop inlet and outlet and city water (emergency water) inlet and drain.

45. The system shall provide a water flow switch on water outlet manifold. In the event that water flow is interrupted for more than 1 second power to the heating element will automatically be shut off. If the water flow is interrupted for more than 5 seconds the cooling will switch to city water (emergency water) system for orderly shutdown.

Load Frame Interface

46. All loading hardware shall be designed to interface with and be installed into the MTS Criterion Model C45.504 Wide test stand

47. The furnace contractor shall supply the 3.5 inch diameter 17-4PH water-cooled stainless steel top and bottom cold rods.

48. The bottom cold rod is stationary and sealed vacuum tight to chamber using static O-Ring. Bottom cold rod can utilize bellows if part of standard design for the manufacturer.

49. The top rod has a bellows assembly with 6.0" stroke. A static O-Ring seal is between bellows assembly and the top cold rod.

50. The top rod will interface with the MTS load cell, with a M27-2 male thread or a M12 x 1.25 thread if the tandem load cell is in use.

Provided Utility Services:

51. Single circuit with up to 100 amps of 3-phase 480 volt power. Additional circuits of up to 50 amps

3-phase 480 volts are available if needed for control or pump systems

52. Cooling tower water of up to 50 GPM at 27°C (Using Low conductivity Deionized Water)

53. City water (emergency use) of up to 50 GPM.

54. Process Gas: Argon, optional Nitrogen or Helium (pressure regulation by customer) up to 50

SLPM.

55. Compressed Air: 90psi filtered (pressure regulation by customer).

Acceptance Testing, Installation, Training and Documentation

56. All equipment will be tested for compliance with specifications. Initial testing can be done at the contractor location or the customers.

57. The contractor shall install the furnace in the MTS stand at NASA Langley Research Center and after installation testing will be conducted to ensure performance of furnace while mounted in the test stand for proper operation.

58. The contractor shall supply operator training.

59. Installation shall be within 10 months of the contract award.

60. The contractor shall supply general installation and operating instructions, digital and or paper copy.

61. The contractor shall supply component manuals for proprietary items, digital and or paper copies.

62. The contractor shall supply general arrangement drawing, digital and or paper copy.

63. The contractor shall supply assembly drawings, digital and or paper copy.

64. The contractor shall supply electrical schematic drawings, digital and or paper copies.

65. The contractor shall supply a list of recommended spares with current prices. Provided at time of order, digital and or paper copy.

66. The contractor shall supply a list of computer based control systems, required to be supplied prior after bid acceptance and prior to final award to allow NASA to clear items for use, digital copy

Priced Options

Group 1, Dual Extensometers

67. (substitute for paragraph 7) The furnace chamber shall have sufficient interior space to allow mounting of extensometers that will reach the center of the hot zone. With enough extra room to fully withdraw the extensometers from the furnace chamber without removing the hot zone.

68. (substitute for paragraph, 19) The system shall be equipped with dual opposing extensometers that can reach the center of the hot zone and operate at temperatures up to 1600°C. The extensometers shall have a gage length of 1-inch (25mm) and have a range of +20 to -10 percent.

The extensometers shall be attached to the test specimens while the front door is open. The extensometers shall not block the view from the front door or rear ports.

Group 2, 3D Surface Analysis Window

69. (substitute for paragraph 10) The furnace chamber shall be equipped with centered front and rear windows with a clear view of at least 2-inches in diameter. The window ports shall have inert gas purge. The windows will be made of high purity quartz (amorphous silica). There will be two additional ports of the same configuration, including gas purge, that are above and below the center window and angled to align with the center of the furnace. The center of these window will be between 10 and 15 degrees off the center line. Optionally a single larger window can be installed that has a clear view at least 12-inches tall and 2 inches wide.

70. (substitute for paragraph 17) The hot zone shall allow viewing of the center of the chamber with a view through the exterior ports of 1/2 inch wide by 2 inches tall from the rear port and a 1-inch wide by 3-inches tall from the front window ports. Three holes through the insulation shall align and be angled to match the three 2-inch windows in the front. The furnace shall include plugs to fill the holes in the insulation when viewing ports are not needed. The furnace shall include a plug for the center front hole that reduces the center hole view from 1 x 3 inches to 0.5 x 2-inches and fills the top and bottom hole completely. If the 12-inch window is used the holes will align with the window center and with a spots on the window on the top and bottom of the window that are 15° from the center line and 3 inches tall. A lower maximum use temperature can be recommended when holes in the hot zone are used for viewing.

Group 3, Dual Pyrometers

71. (substitute for paragraph 11) The furnace chamber shall be equipped with dual front ports with a windows at least 1.5 inches in diameter with a clear view of the center of the furnace for mounting pyrometers. These windows will not be in the center of the door or rear of the chamber and the window ports will need to be angled to align with the center of the furnace. The windows will be made of high purity quartz (amorphous silica).

72. (substitute for paragraph 18) The hot zone shall allow viewing of the center of the hot zone from both pyrometer widows with a hole at least 5/8th inch in diameter.

73. (substitute for paragraph 38) The furnace shall be equipped with two 2-color optical pyrometers, with a temperature range of, at a minimum, 1000° -2400°C. One pyrometer is used for furnace temperature control above 1700°C the second for observation.

74. (substitute for paragraph 39) The pyrometers will be mounted to the furnace with adjustable mounts so that the exact temperature reading spot can be adjusted a small amount.

Group 4, Center Deflection Rod

75. (substitute for paragraph 16) The hot zone shall be equipped with two replaceable graphite rods 3-inches in diameter that attach to the top and bottom water-cooled steel push rods and will meet 3-inches below the furnace center with the crosshead at its minimum position and have 6-inches of clearance centered in the hot zone when the crosshead is at its maximum position. The lower ram shall be hollow to allow for the passage of a easily replaceable graphite rod, ¼-inch diameter, that can reach the center of the hot zone. The 3.5-inch lower cooled steel rod shall be equipped with a hollow space to allow the installation of a contractor supplied LVDT, or similar position indicator, and alignment bushings. The LVDT shall be attached to the graphite rod. The LVDT shall have a travel of at least 0.5 inches and have a spring to hold the rod against the bottom of the test specimen. The chamber shall contain an electrical port to allow the LVDT to connect to the MTS control system.

Group 5, 2300°C Max Temperature

76. (substitute for paragraph 5) The furnace shall allow mechanical testing from room temperature to 2200°C in an inert atmosphere.

77. (substitute for paragraph 12) No spot on the exterior surface of the chamber shall exceed 70°C, handles and knobs shall not exceed 55°C while the furnace is at maximum temperature or after 1 hour at 2200°C

78. (substitute for paragraph 15) The hot zone shall be able to achieve a temperature of 1700°C for testing, with a hold duration of 1 hour or greater, with a maximum temperature of 23000°C. The hot zone shall have a temperature uniformity over a central work volume of 10 inches diameter by 8 inches tall using an argon atmosphere from 800°C to 1650°C of ±10°C

79. (substitute for paragraph 33) The power supply shall have sufficient power to heat the hot zone to 2000°C within 80 minutes and have the hot zone reach a maximum temperature of 2300°C within 100 minutes.

80. (substitute for paragraph 38) The furnace shall be equipped with a 2-color optical pyrometer, with a temperature range of, at a minimum, 1000° -2400°C. The pyrometer is used for furnace temperature control above 1700°C.

Group 6, Cooling System

81. If the system requires more than 50 GPM of cooling water flow or lower input temperatures the system will be supplied with an independent cooling system.