Tab 04 SOW.pdf

Scope of Work

3.1 Collect exis ng data of raw AM anomalies and fa gue valida on data.

The previous effort focused on an AM AlSi10Mg dataset from AFRL. We adopted this dataset because it was readily available at the beginning of the project, not because it was par cularly applicable to any specific NASA applica on. There are other common AM alloys with exis ng data in the open literature, in government databases, and (poten ally) available from commercial clients. Specifically, there are at least two major sources of raw data suitable to construct anomaly exceedance curves:

• NASA funded ac vi es at the ASTM AM Center of Excellence at Auburn University.

• NASA funded Space Technology Research Ins tute (STRI) led by Carnegie Mellon University (CMU) and

Johns Hopkins University (JHU).

In this task, Contractor would determine available AM datasets that could be used to construct exceedance curves and to validate fa gue life predic ons from these exceedance curves. Contractor would focus on the two ins tu ons shown above and work with them to provide Contractor with the relevant data. Alloys would be selected in consulta on with NASA based on NASA’s interest as well as availability of raw AM anomaly inputs and fa gue test data.

3.2 Process alterna ve data sets of different alloys into anomaly distribu ons In this task, Contractor would apply the methodologies described in the previous effort to the AM alloys collected in the previous task. Contractor would generate exceedance curves for this data using rou nes developed during the prior effort. These rou nes include various decision points that impact the exceedance curves as shown in Figure 1. We will examine the impact of these decision points on exceedance curves produced for the selected metallic alloys. Contractor will report this informa on to NASA and will provide the resul ng exceedance curves to NASA.

3.3 Compare results from fa gue life predic ons against valida on data The previous effort by Contractor did not evaluate the impact of the different exceedance curves (shown in Figure 1) on fa gue predic ons. (This work was performed by NASA and not shared with Contractor.) Consequently, we have not evaluated the impact of these decision points on predicted fa gue performance and validated these predic ons against test data.

In this task, we will evaluate the viability of PDT methodology against exis ng test data. Exceedance curves produced in the second task will be input into risk assessments in DARWIN to produce fracture risk vs. life curves. Contractor will then compare life es mates from DARWIN against measured lives. We an cipate that the geometries used in this effort will match conven onal fa gue life specimens with simple loading schemes, and this will reduce the burden of the assessment in DARWIN. Contractor will report results from these studies to NASA and provide NASA with the DARWIN input and output files.

4 Schedule

4.1 Overview

We an cipate that this project will require approximately six months to complete. Nominally, we an cipate a start date of July 1, 2025 and an end date of December 31, 2025 for a total of 26 weeks. The rough schedule of this project is as follows:

• Week 1: Kickoff mee ng

• Weeks 2-3: Iden fy available AM datasets

• Weeks 4-6: Collect, review, and finalize AM datasets

• Weeks 7-13: Process AM datasets into anomaly exceedance curves suitable for DARWIN

• Weeks 13-22: Perform DARWIN life predic ons

• Weeks 23-26: Write final report

Note that this is an extremely aggressive schedule. To complete this effort, Contractor will require help from NASA to facilitate the iden fica on of AM datasets and to collect them in a mely manner.

4.2 Repor ng

Contractor proposes a kick-off mee ng in the first week of the project that will include a dra plan of work. Contractor will inform NASA of progress in monthly virtual mee ngs. There will be a final mee ng at the conclusion of this effort to summarize ac vi es and to close out the project.

4.3 Deliverables

The primary deliverable from this project will be a final report summarizing the inves ga ons and results of the two tasks. It will be provided to NASA at the conclusion of this project. Slide decks prepared for the monthly updates will provide addi onal deliverables to NASA. With NASA permission, selected results may be presented at a suitable AM workshop, conference, or wri en into a journal ar cle.