TDM-25-22N-SOW-0002.pdf

TDM-25-22N-SOW-0002, Revision (-)

22N Non-Toxic Thruster Statement of Work

National Aeronautics and Space Administration

5N/22N Thruster Project Reviewed Not Subject To Export Control

Thruster SOW TDM-25-22N-SOW-0001 Rev (-) ii Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Preface This document is under configuration control. Changes to this document require prior approval of the Configuration Control Board (CCB) Chairperson or designee. Proposed changes shall be submitted with supportive material justifying the proposed change. Changes to this document will be made by complete revision.

iii Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Change History Log

Revision Effective Date

Description of Changes (Reference the CCR & CCB/ERB Approval Date)

(-) 4/29/2025 Baseline Revision iv Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Table of Contents

1.0 Introduction

1.1 General Information

1.2 Scope

1.3 Related documentation

1.4 Applicable documents

2.0 Management, Reporting, Reviews, and documentation

2.1 Program management

2.2 Reporting

2.3 Advanced Notifications

2.4 Reviews And Meetings

2.4.1 Kick-off Meeting

2.4.2 Design Review (DR)

2.4.3 Acceptance Test Readiness Review

2.4.4 Qualification Test Readiness Review

2.4.5 Pre-Ship Review (PSR)

2.4.6 Technical Interchange Meetings (TIM)

2.5 Documentation

2.6 NASA Furnished Data, Equipment, And Facilities

2.7 Existing Documentation and Analysis

3.0 Design And Analysis

3.1 Interface Documentation

3.2 Interface Control Documentation

3.3 Drawing Package

3.4 Computer Models

3.5 Structural Analysis Report

3.6 Structural Finite Element Model

3.7 Thermal Analysis Report

3.7.1 Catalyst Bed/Reactor Analysis

3.8 Thermal Model and Documentation

3.9 Worst Case Circuit Analysis Report

3.10 Parts Stress Analysis Report

3.11 Reliability Analysis Report

3.12 Failure Modes And Effects Criticality Analysis Report

3.13 User/Instruction Manuals

4.0 Hardware Procurement/Manufacturing

4.1 General Requirements

4.2 Thruster

4.3 Ground Support Equipment

5.0 Performance Verification And Test

5.1 Verification

5.2 Verification plan

5.3 Verification Methods

5.3.1 Inspection

5.3.2 Analysis

5.3.3 Test

v Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

5.4 Inspection requirements

5.4.1 Visual Inspection

5.4.2 Physical Measurement

5.4.3 Documentation Search

5.5 analysis requirements

5.6 test requirements

5.6.1 Definitions

5.6.2 Thermal Cycle Prior to Structural Testing

5.6.3 Non-Destructive Examination

5.6.4 Verification Test Procedures

5.6.5 Verification Test Reports

5.6.6 Test Factors

5.6.7 Test Tolerances

5.6.8 Test Restrictions

5.6.8.1 Failure During Test

5.6.8.2 Modification of Hardware

5.6.8.3 External Adjustment

5.6.8.4 Re-Test Requirements

5.7 Required tests

5.7.1 Physical Inspection

5.7.2 Mass Properties Measurement

5.7.3 Proof Pressure

5.7.4 Performance

5.7.5 Frequency Signature Survey

5.7.6 Static Loads/Strength

5.7.6.1 Sine Burst

5.7.6.2 Static Pull

5.7.7 Sine Vibration

5.7.8 Random Vibration

5.7.9 Shock

5.7.10 Thermal Vacuum Test

5.7.10.1 Thermal Vacuum Test Parameters

5.7.10.2 Thermal Cycle Test Profile

5.7.10.3 Catalyst Bed / Reactor Test

5.7.11 Continutiy/Hi-Pot Tests

5.7.12 Hot Fire Testing

5.7.12.1 Acceptance Hot Fire Testing

5.7.12.2 Qualification Hot Fire

5.7.13 Grounding

5.7.14 Alignment

5.7.15 Cleanliness

6.0 Safety and mission Assurance

6.1 General Requirements

6.1.1 Quality Assurance Plan/Manual

6.1.2 Configuration Management

6.1.3 Training and Certification of Personnel

vi Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

6.1.4 Surveillance of the Contractor

6.1.5 Source Inspections

6.1.6 Goverment Mandatory Inspection Points (MIPs)

6.1.7 Anomaly Reporting

6.1.8 Ground Support Equipment Interfaces

6.2 Reliability Requirements

6.2.1 Limited-Life Items

6.3 Design Verification Requirements

6.3.1 Verification Requirements

6.3.2 Analysis, Trending, and Reporting of Test Data

6.4 Workmanship Standards and processes

6.4.1 General

6.4.2 Workmanship: Use of Alternate Workmanship Standards

6.5 Materials, Processes Requirements

6.5.1 Materials and Processes Control

6.5.2 Commercial-Off-The-Shelf (COTS), Vendor-Designed and Fabricated, and Bilateral Agreement Furnished Hardware

6.5.3 M&P Usage Documentation

6.5.4 Materials Usage Agreements (MUAs)

6.5.5 Detailed Requirements

6.5.5.1 Adhesive Bonding (NASA-STD-6016 Section 4.2.4.3)

6.5.5.2 Additive Manufacturing

6.5.5.3 Material Evaluation Plan (NASA-STD-6016A Section 4.2.5.1)

6.5.5.4 Fastener Installation (NASA-STD-6016A Section 4.2.6.6)

6.5.5.5 Liquid Locking Compounds (NASA-STD-6016A Section 4.2.6.6.1)

6.5.5.6 Contamination Control (NASA-STD-6016 Section 4.2.6.6)

6.5.5.7 Packaging (NASA-STD-6016A Section 4.2.6.8)

6.5.5.8 Shelf-Life Items

6.5.5.9 Materials Procurement Requirements

6.6 Contamination Control Requirements

6.6.1 Contamination Control Plan

6.6.2 Surface Cleanliness

6.6.3 Material Outgassing

6.7 Metrology

6.7.1 General

6.7.2 Use of Calibrated and Non-calibrated Instruments

7.0 Handling, Storage, Packaging, Preservation, and Delivery

Appendix A. Deliverable Items list and schedule Appendix B. Abbreviations and acronyms vii Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

List of Tables

Table Page

Table 4-1 FMEA Severity Categories Figure 5-1: Thermal Vacuum Profile

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

1.0 INTRODUCTION

1.1 GENERAL INFORMATION

The Space Technology Mission Directorate (STMD) Technology Demonstration Office (TMD) is investigating low toxicity propulsion in the 22N thrust levels for direct applications to NASA Science Mission Directorate (SMD) mission applications.

This document defines the work to be performed by the Contractor in the design, development, fabrication, and delivery of a 22N liquid rocket engine using non-toxic propellant. From here on referred to as the thruster.

1.2 SCOPE

The contractor shall provide the facilities, personnel, services, tools, equipment, and materials necessary to design, analyze, manufacture, test, and deliver the hardware and data in accordance with the requirements of this SOW and the documents referenced herein.

This Statement of Work (SOW) defines requirements that govern the management, development, testing, qualification and delivery of the 22N thruster. It defines the contractor tasks, deliverables, responsibilities, and schedule, either within this document or by reference. More details for the Deliverable Items List and Schedule (DILS) are contained in Appendix A.

1.3 RELATED DOCUMENTATION

In the event of a conflict between the SOW and the specification (SPEC), the SOW shall take precedence.

1.4 APPLICABLE DOCUMENTS

The following documents are referenced within this document and are directly applicable or contain policies or other directive matters that are binding for the contents of this document. In the event of conflict between an Applicable Document and the content of this document, NASA has the final authority for conflict resolution.

Document Number Title TDM-25-22N-SPEC-0002 22N Non-Toxic Thruster Specification 541-PG-8072.1.2C Goddard Space Flight Center Fastener Integrity

Requirements

NASA-STD-6016A Standard Materials and Processes Requirements for Spacecraft

GSFC EEE-INST-002 Instructions for EEE Parts Selection, Screening, Qualification, and Derating

GSFC-STD-1000G Rules for the Design, Development, Verification, and Operation of Flight Systems

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Document Number Title GSFC-STD-7000A General Environmental Verification Standard (GEVS) for GSFC Flight Programs and Projects

NASA-STD-6008 NASA Fastener Procurement, Receiving Inspection, and Storage Practices for Spaceflight Hardware

NASA-STD-8719.24 NASA Expendable Launch Vehicle Payload Safety Requirements

NASA-STD-8739.4 Workmanship Standard for Crimping, Interconnecting Cables, Harnesses, and Wiring

MSFC-SPEC-445A Adhesive Bonding, Process and Inspection, Requirements for

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

2.0 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 PROGRAM MANAGEMENT

The contractor shall provide the facilities, personnel, services, tools, equipment, and materials necessary to design, analyze, manufacture, test, and deliver the hardware and data in accordance with the requirements of this SOW and the documents referenced herein.

The contractor shall generate a matrix listing each Section in this statement of work reflecting either compliance or non-compliance. (DIL #1) Areas of non-compliance need to be addressed by the contractor showing how they plan to meet the requirement(s) or why it will remain non-compliant.

The contractor shall designate a single individual who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule and cost constraints.

The contractor shall designate and identify by name a single individual who shall serve as a point of contact with NASA Contracting Officer’s Representative (COR) for all technical aspects of the thruster contract.

The contractor shall establish and apply a program control system for managing all resources, controlling schedules, managing all engineering, manufacturing and procurement activities, configuration management, Quality Assurance, documentation control, and distribution.

2.2 REPORTING

The contractor shall generate a list of significant milestones that will enable the NASA COR to ascertain program progress. (DIL #2)

The contractor shall report status verbally in weekly telecons with the NASA COR.

The contractor shall prepare and present to the NASA COR monthly technical status reports.

(DIL #3) The report shall be a summary presentation of the period's progress to include topics such as schedule overview, accomplishments, technical performance measures (e.g. mass and power), status of key milestones, a running action item log, risks, problem areas, challenges/issues, quality assurance issues/status, and activities on-going and planned.

2.3 ADVANCED NOTIFICATIONS

The contractor shall notify the NASA COR at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, technical interchange meetings (TIMs), and deliveries at either the contractor’s or a sub-contractor’s facility to allow timely participation by the NASA and/or Quality Assurance representative. (DIL #4) Event specific notification requirements (such as failures, anomalies, etc.) are included in the appropriate Sections in this

SOW.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

2.4 REVIEWS AND MEETINGS

2.4.1 Kick-off Meeting

The Contractor shall organize and hold a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW. (DIL #5)

The Contractor shall provide to the NASA COR a Kick-off Presentation Package and all other required deliverables. (DIL #6)

The Kick-off Meeting shall address program management and quality assurance activities outlined in this SOW, as well as the performance and environmental requirements outlined in the Thruster specification (TDM-25-22N-SPEC-0002) in sufficient detail to demonstrate understanding of contract requirements.

At a minimum, the presentation package should cover the following areas:

• Program Management

• Quality Assurance

• Thruster Design Description

• Preliminary Interface Control Documents

• Flight Heritage

• Fabrication, Assembly, and Inspection Flow plan

• Facilities

• Qualification Verification Plan and Procedure

• Any long-lead items that need to be ordered prior to Design Review

2.4.2 Design Review (DR)

The contractor shall organize and present a Design Review (DR) to a NASA Review Team at the contractor’s facility prior to the manufacturing program. (DIL #7)

The contractor shall provide to the NASA COR a Design Review Presentation Package and all other required deliverable data prior to the review. (DIL #8)

The Design Review shall address all program management, design, drawings, analysis, manufacturing, test, and quality assurance activities outlined in this SOW and the Thruster Specification, (TDM-25-22N-SPEC-0002), in sufficient detail to ensure that the proposed design conforms to all requirements.

The Design Review shall demonstrate that the 22N thruster design qualification is achievable based on the Thruster Specification (TDM-25-22N-SPEC-0002) requirements.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

At a minimum, the design package should cover the following areas:

• Program Management

• Quality Assurance

• Electrical, Mechanical, and Environmental specifications

• Manufacturing flow with Government Mandatory Inspection Points identified

• Acceptance Verification Test Plan (Including Performance Test Descriptions)

• Qualification Verification Test Plan (Including Performance Test Descriptions)

• Materials and Processes List (as-designed)

• Interface Control Documents

• Mechanical STEP Model

• Mechanical/Structural Analyses

• Thermal Analyses to show ability to not overheat valve or chamber

• Performance Analyses (preliminary)

• Catalyst life analyses / thruster testing to show ability to meet propellant throughput

• Parts, including stress analysis and radiation hardness assessment

• Facilities

• Contamination Control

• Electrical Worst-Case analyses

• Failure Modes Effects Criticality Analysis

• Thruster operational constraints document (preliminary)

• Flight Heritage

• Specification Verification Matrix (per Section 6.3)

• List and status of all identified Life-Limited Items

The contractor shall prepare review minutes including, as a minimum, attendance, action items, action item accomplishment responsibility, and agreements. All items shall be in sufficient detail to be self-explanatory. A Design Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items. (DIL #9)

2.4.3 Acceptance Test Readiness Review

The contractor shall hold an Acceptance Test Readiness Review (ATRR) at the contractor's facility prior to starting Thruster acceptance testing. (DIL #10)

The contractor shall demonstrate that all hardware manufacturing steps are complete, show that all analysis verifications are complete, show readiness of all activities required for testing, and describe in detail any activities that are not yet ready with a completion schedule for each.

In particular, the contractor shall present the updated specification verification matrix and all test procedures. The NASA COR and customer technical team will attend the ATRR.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

The ATRR package shall be delivered to the NASA COR, unless otherwise stated. (DIL #11)

All Acceptance Test Procedures shall be submitted to the NASA COR. (DIL #12)

The specific pre-acceptance testing data shall also be provided at the ATRR.

At a minimum, the ATRR package shall address:

• Summary of hardware manufacturing results

• Any non-conformances and problem reports

• Any changes in design or manufacturing

• As-built materials and processes, including as-built material certifications

• Specification verification matrix

• The list of tests to be conducted as part of the overall procedure

• All procedures required for the tests

• Availability of facilities and personnel

• Special test equipment, e.g., for hot and cold tests

• Accuracy of instruments used to record test data

• How the tests are monitored and signed off

• Accept / reject criteria for each test

• How the data results are recorded and transmitted to the customer

• Current hardware status, including build paperwork

• Any risks associated with each test including safety risks, risks in not obtaining accurate data, or any other risk which it is appropriate to discuss

Review minutes shall be prepared and delivered to the NASA COR after the meeting. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility, and agreements. (DIL #13)

2.4.4 Qualification Test Readiness Review

The contractor shall hold a Qualification Test Readiness Review (QTRR) at the contractor's facility prior to starting qualification testing. (DIL #14)

The contractor shall demonstrate that all qualification hardware manufacturing steps are complete, show that all analysis verifications are complete, show readiness of all activities required for testing, and describe in detail any activities that are not yet ready with a completion schedule for each.

In particular, the contractor shall present the updated specification verification matrix and all test procedures. The NASA COR and customer technical team will attend the QTRR.

The QTRR package shall be delivered to the NASA COR, unless otherwise stated. (DIL #15)

All Qualification Test Procedures shall be submitted to the NASA COR. (DIL #16)

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

At a minimum, the QTRR package shall address:

• Summary of qualification hardware manufacturing results

• Any non-conformances and problem reports

• As-built materials and processes, including as-built material certifications

• Specification verification matrix

• All procedures required for the qualification tests

• The list of tests to be conducted as part of the overall procedure

• Availability of facilities and personnel

• Special test equipment, e.g., for hot and cold tests

• Accuracy of instruments used to record test data

• How the tests are monitored and signed off

• Accept / reject criteria for each test

• How the data results are recorded and transmitted to the customer

• Any risks associated with each test including safety risks, risks in not obtaining accurate data, or any other risk which it is appropriate to discuss

Review minutes shall be prepared and delivered to the NASA COR after the meeting. The minutes shall include at a minimum, attendance, action items, action item accomplishment responsibility, and agreements. (DIL #17) The scope of the QTRR shall include any testing that is performed during the assembly process.

2.4.5 Pre-Ship Review (PSR)

The contractor shall hold a Pre-Ship Review at the contractor's facility at the completion of verification tests and prior to the shipment of each hardware item to NASA. (DIL #18)

This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to NASA and note any activities that are incomplete. (DIL #19)

In particular, the contractor shall present the completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable. (DIL #20) Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with NASA during the review.

An End Item Data Package (EIDP) shall be made available for review during pre-ship reviews for each of the different hardware deliverables. (DIL #21)

This package shall also be delivered with each end item with the level of detail required of that item. The package should be comprised of, but not limited to, the following data:

• The deliverable item name, serial number, part number, and classification status (e.g., flight, non-flight, ground support)

• Appropriate approval signatures (e.g., contractor’s quality representative, product design lead, government Representative)

• Work orders for the final assembly and associated tests

• As-Built Parts List (EEE parts, includes serialization/revisions)

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

• As-Built Final Drawing Package (including rework instructions, if any)

• Problem/anomaly reporting (complete copies of report)

• Deviations/Waivers/shortages/open items/non-conformances and their dispositions, with supporting rationale

• Status of all action items from previous reviews

• Class I MRBs (complete copies of reports)

• List of As-Built Materials and Processes used

• Achieved surface cleanliness and outgassing rate data (when applicable)

• Log of total operating time and failure-free operation, separated by primary/redundant sides, if any

• Hot fire results

• Performance analysis (final)

• Thruster operational constraints document (final)

• List and status of all identified Life-Limited Items, including data regarding the life used and remaining

• Total number of mechanical cycles and remaining cycle life

• Trended Critical Parameters Data (when applicable)

• Specification verification matrix, test data and reports (including qualification test report)

• Acceptance test results

• Calibration data for thermal sensors

• List of open items with reason for item(s) being open and proposed closure date

• Photograph Documentation (Pre-Closure and Closed)

• Certificate of Conformance, with management signature; includes manufacturer’s name and address; part number and revision number; batch identification such as date codes, lot codes, serializations; signature or stamp of authorized personnel; purchase order or contract number; contamination certificates of compliance, etc.

• End Item Inspection Report

• As Built Configuration List

• Storage and Transportation Plans and Requirements

2.4.6 Technical Interchange Meetings (TIM)

The contractor shall plan for and facilitate up to three (3) informal, face-to-face technical interchange meetings to be held at the contractor facilities. (DIL #22) These TIMs shall support review and coordination of technical issues including, but not limited to, parts, test plans, test procedures, software changes, design modifications, and design analyses.

2.5 DOCUMENTATION

The contractor shall ensure the generation and delivery of all documentation as called for in the contract and listed in Appendix A.

In addition to that documentation specifically called for in the contract, upon request by the NASA COR, the contractor shall make available a copy of any document or data generated during this contract performance for review by NASA at either the contractor's facility or via the

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

internet. This includes, but is not limited to, technical reports and memorandums, drawings, schematics, studies, analyses, parts and materials data, test data, alerts, etc.

2.6 NASA FURNISHED DATA, EQUIPMENT, AND FACILITIES

N/A

2.7 EXISTING DOCUMENTATION AND ANALYSIS

If analysis or documentation exists already for that satisfies the requirements within the Thruster Specification (TDM-25-22N-SPEC-0002) and the descriptions in Section 3.0, then the analysis or documentation may not need to be redone, and the requirement can be satisfied by similarity and with the delivery of the previous analysis/documentation to the NASA COR.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

3.0 DESIGN AND ANALYSIS

The contractor shall perform analyses of the technical and environmental requirements specified in the Thruster Specification (TDM-25-22N-SPEC-0002), to ensure compliance of the hardware fabrication and to assemble the documentation necessary to ensure its usability by NASA.

Previous analyses may be submitted for the items below per Section 2.7.

3.1 INTERFACE DOCUMENTATION

The contractor shall use metric units when interfacing with NASA including any drawings, documents, models, except for the following cases:

• SI units with parenthetical English units are permitted for engineering and manufacturing drawings.

• Angular measurement may be expressed in degree of arc or in an appropriate subdivision of degree of arc such as minute or second of arc (arc-min or arc-sec).

• Hardware that has been previously built, or new hardware of similar design heritage, may be specified in English units where use of metric equivalents would lead to additional risk and cost to the program, but interfaces with that hardware must use metric with parenthetical English units.

• Although bolt patterns will be defined using metric dimensioning, use of English fasteners (with hole dimensioning and tolerancing) is permitted.

3.2 INTERFACE CONTROL DOCUMENTATION

The Contractor shall provide the following documents (DIL #23):

• Mechanical Interface Control Document (MICD), including physical characteristics, mounting interface, outline drawing, thermal coatings on surfaces

• Electrical Interface Control Document (EICD), including connector identification, connector pinouts, detailed description of each signal, interface circuits, command description, command sequencing/timing

• This can be either a single document or multiple documents.

The Contractor shall include, at least, the following items in the ICD:

• Mounting clearances

• Voltage

• Resistances

• Wire colors

• Center of Mass

• Temperatures

• Piece part IDs for heaters, thermistors, and thermal sensors

• Wiring Diagram

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

3.3 DRAWING PACKAGE

The contractor shall provide a drawing package that includes, but is not limited to: (DIL #24)

ELECTRICAL: assembly and interface drawings MECHANICAL: assembly and interface drawings

The complete drawing package shall be available for review at the Contractor’s facility (for DR).

3.4 COMPUTER MODELS

The contractor shall deliver the following computer models: (DIL #25)

a) A native Computer-Aided Design (CAD) file for the thruster

b) A Mechanical Model in STEP file format

c) Thermal model (see Section 3.7)

3.5 STRUCTURAL ANALYSIS REPORT

A Structural Analysis shall be provided for the Thruster structure to ensure the capability to withstand and survive launch and ascent loads. (DIL #26) The effects of any thermal inputs shall be reflected in the analyses as appropriate. The analysis shall also address loads on any lift points as well. For metallic elements whose strengths are to be qualified by analysis (rather than by test, subject to NASA approval), margins of safety will be 2.0 on yield and 2.6 on ultimate.

Beryllium and composite materials shall not be qualified by analysis alone.

The purpose of the structural analyses is to demonstrate compliance with the mechanical/structural design and test requirements. Structural analyses verify the structural integrity of the flight hardware by assessing the size and location of applied loads, load paths, and critical failure modes.

The results of these analyses shall be summarized in a contractor format Structural Analyses Report that will be provided to the NASA COR for review.

3.6 STRUCTURAL FINITE ELEMENT MODEL

Contractors shall submit a finite element model that supports the conclusions in their structural analysis report. (DIL #27)

3.7 THERMAL ANALYSIS REPORT

The contractor shall provide a thermal analyses to demonstrate compliance with the thermal requirements and boundary conditions specified in the Thruster Specification (TDM-25-22N- SPEC-0002) (DIL #28) Specific requirements to be analyzed or to be known include:

• Normal Performance at Survival Temperatures

• Temperature Measurements for both Valve and Catalyst Bed / Reactor

• Heat Soakback Analysis

• Valve Over-heating

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

• Thorough description of all Boundary Conditions and Material Properties

• Steady-State Firing Temperature

• Thruster Temperature vs. Duty Cycle at multiple locations including Valve and Catalyst

Bed / Reactor

All analysis results shall be summarized in a Contractor format for the Thermal Analyses Report, to be provided for review as per the contract schedule. Additionally, this report shall contain a thorough description of the computer models (or reference to the documentation required from Section 3.7 Thermal Model and Documentation) and the assumptions that were used to perform the analysis including boundary conditions, Beginning-of-Life and End-of-Life surface finish thermo-optical properties, and interface conductances.

3.7.1 Catalyst Bed/Reactor Analysis

The analyses described in this Section may be included as part of the thermal analysis report (DIL #28) or may be a separate catalyst bed/reactor heating analysis report (DIL #29).

The contractor shall provide performance analyses for the Catalyst Bed / Reactor heaters, including calculating time to reach minimum firing temperature from the minimum cold non-operational temperature.

The analysis shall include warm-up predictions with a single Catalyst Bed / Reactor heater operating and additionally, with both Catalyst Bed / Reactor heaters operating.

The contractor shall provide a pre-launch catalyst bed heating analysis, which determines how long the catalyst bed heaters (single and both) can operate in the ground environment (air) without affecting the catalyst performance. Certain missions require strategic launch plans which includes initiating catalyst bed heating shortly before launch to enable contingency spacecraft recovery thruster maneuvers are needed.

The analysis shall include discussion of catalyst bed degradation indicators based on this launch configuration.

3.8 THERMAL MODEL AND DOCUMENTATION

The contractor shall provide reduced Thermal Math Models (TMMs) for the Thruster with less than 50 nodes per box. Thermal Desktop/SINDA format or another format pre-approved by the

NASA (DIL #30).

If the contractor does not have the project-compatible software to create TMMs, then the contractor shall provide sufficient detailed information such that NASA can create the TMMs.

Documentation shall be provided including detailed descriptions of all aspects of the model necessary for NASA to run and/or recreate the TMMs.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

3.9 WORST CASE CIRCUIT ANALYSIS REPORT

The contractor shall perform worst-case analyses (WCA) for newly designed or modified circuits. (DIL #31) This element has been identified as warranting a Worst Case Analysis, since it has performance critical or function critical components for which excessive operating variations could compromise performance. They include control loops that require adequate phase and gain margin to operate properly, sensitive analog circuitry, power supply or switching circuitry, Field Programmable Gate Arrays, motor and actuator systems, and electro-mechanical elements that require torque margin to operate over life and environmental variations. The result is “reliability is designed into the hardware” for long term trouble-free field operation (i.e., removal of adverse operational circuit behavior due to unanticipated component stress drift).

WCA shall be performed during the design phase by the design engineer. The Worst Case Analysis Report shall include the following:

- Address worst case conditions performed on each component.

- Discuss how each analysis includes the mission life.

- Discuss consideration of critical parameters at maximum and minimum limits.

- The effect of environmental stresses on the operational parameters being evaluated.

The results of these analyses shall be summarized in a Contractor format Worst Case Circuit Analysis Report that will be provided to the NASA for review.

3.10 PARTS STRESS ANALYSIS REPORT

The contractor shall perform parts stress analyses on Electrical, Electronic, and Electromechanical (EEE) parts and devices as employed in the circuit designs of the Flight Item to certify conformance with the derating requirements of EEE parts. (DIL #32)

The analyses shall be documented, and justification shall be included for all applications that do not meet the derating criteria. The Contractor shall use NASA document EEE-INST-002, Instructions for EEE Parts Selection, Screening, Qualification, and Derating to establish criteria.

Contractor derating guidelines may be considered in place of EEE-INST-002 guidelines but shall be submitted for approval. (DIL #33) The results of these analyses shall be summarized in a Contractor format Parts Stress Analysis Report that shall be provided to the NASA for review.

3.11 RELIABILITY ANALYSIS REPORT

The contractor shall perform comparative numerical reliability assessments and reliability predictions (DIL #34) to:

a. Evaluate alternative design concepts, redundancy, cross-strapping approaches, and part substitutions as applicable

b. Identify the elements of the design that are the greatest detractors of system reliability

c. Identify those potential mission limiting elements and components that will require special attention in part selection, testing, environmental isolation, and/or special operations

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

d. Assist in evaluating the ability of the design to achieve the mission life requirement and other reliability goals and requirements as applicable

e. Evaluate the impact of proposed engineering change and waiver requests on reliability

f. Estimate the reliability (probability of success) of the Thrusters

The results of this analysis shall be summarized in a Contractor format Reliability Analysis Report that will be provided to the NASA for review.

3.12 FAILURE MODES AND EFFECTS CRITICALITY ANALYSIS REPORT

The contractor shall perform an FMECA (Failure Modes and Effects Criticality Analysis) to identify potential failures with severity categories 1, 1R, 1S, 2, 2R, 3, and 4 per Table 4-1. (DIL #35)

The FMECA shall be updated throughout the development life cycle to address design changes that result in changes to failure modes, causes, effects, system impact, or to mitigation status and corresponding retention rationale. FMECA shall be performed at the interface and functional level of the component.

The contractor shall prepare and maintain a critical items list (CIL) for severity categories 1, 1R, 1S, and 2 per Table 4-1.

The contractor shall:

• Analyze failure modes resulting in severity categories 1, 1R, 1S, or 2 to determine the potential cause, corresponding mitigation actions, and retention rationale.

• For each item on the CIL that is not addressed by having a Corrective Action taken which reduces the severity category to a 2R, 3 or 4, there shall be a retention rationale prepared/recorded which contains data that supports the premise that the risk presented by inclusion of the item in the design has been minimized by one or more of the following: detailed evaluation of probability of occurrence; proper design controls, inspections, and tests; and that no adverse failure history exists. The rationale also will contain data that describes operational constraints caused by occurrence of the failure and any measures that can be taken to restore the function on orbit.

• Identify and assess common cause failure modes and causes for category 1R and 2R items

• Address flight hardware and software that is designed, built, or provided by their organization or subcontractors, from project initiation through launch and mission operations.

• Address the ground system that interfaces with flight equipment to the extent necessary to assure the integrity and safety of flight items.

• Identify and address safety critical software.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

Table 4-1 FMEA Severity Categories

Category Severity Severity Description

Catastrophic

Failure modes that could result in serious injury, loss of life (flight or ground personnel), or loss of launch vehicle.

1R Failure modes of identical or equivalent redundant hardware items that could result in Category 1 effects if all failed.

1S Failure in a safety or hazard monitoring system that could cause the system to fail to detect a hazardous condition or fail to operate during such condition and lead to Category 1 consequences.

Critical

Failure modes that could result in loss of one or more mission objectives as defined by the NASA COR.

2R Failure modes of identical or equivalent redundant hardware items that could result in Category 2 effects if all failed.

3 Significant Failure modes that could cause degradation to mission objectives.

4 Minor Failure modes that could result in insignificant or no loss to mission objectives

We are considering the loss of a single string component to be a category 2 and the loss of a redundant component to be a 2R.

The results of these analyses shall be summarized in a Contractor format Failure Modes and Effects Criticality Analysis Report that shall be provided to the NASA for review.

3.13 USER/INSTRUCTION MANUALS

The contractor shall deliver procedures that describe the operation of the thruster and any operational constraint in order to prevent unintentional damage to the flight hardware (DIL #36).

Examples of items to include in the user/instruction manuals are safe handling, long-term storage activities, operational constraints for voltage, temperature, number of cycles, hold open procedures, installing and using the optical alignment fixture, and installing and using the leak test fixture.

If there are limitations on thruster operation with respect to roughness, the contractor shall describe the limitations, the technical basis for the limitations, and the risks associated with thruster operation at the limiting conditions.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

4.0 HARDWARE PROCUREMENT/MANUFACTURING

4.1 GENERAL REQUIREMENTS

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the Thruster to support the delivery dates as called for in the contract and listed in Appendix A.

The contractor shall assemble the quantities of Thruster hardware described below.

The contractor shall provide a Fabrication, Assembly, and Inspection Flow plan at the DR that shall include a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled Thruster.

4.2 THRUSTER

The contractor shall provide the following hardware to meet the requirements of the Thruster Specification (TDM-25-22N-SPEC-0002).

a) One (1) Thruster Flight Qualification Unit (DIL #55)

b) One (1) Valve Qualification Unit (DIL #56) if necessary to satisfy requirements in TDM-

25-22N-SPEC-0002

The contractor shall include in the proposal the cost to purchase all hardware including all supporting hardware.

4.3 GROUND SUPPORT EQUIPMENT

The Contractor shall provide the following Ground Support Equipment:

• One (1) Nozzle Test Plug -- (with AN interface) for valve testing purposes that seals against the nozzle such that valve leakage and flow testing may be performed. (DIL #57)

• One (1) set of Alignment Hardware -- for measuring the alignment of the thruster’s nozzle on the spacecraft. (DIL #57)

• One (1) Red Nozzle Cover -- protective covers to prevent incidental damage to the nozzle

(DIL #57)

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

5.0 PERFORMANCE VERIFICATION AND TEST

5.1 VERIFICATION

The contractor shall conduct a verification program that demonstrates the component design is qualified. The contractor will provide a verification matrix defining the method of verification for each specific requirement of this document.

5.2 VERIFICATION PLAN

A Verification Plan shall be generated by the contractor to describe the details of how the analyses, inspections, and verification tests identified in the Thruster Specification TDM-25- 22N-SPEC-0002 will be performed. (DIL #37) Verification tests shall demonstrate the thruster meets all of the specified performance requirements over the specified range of environments, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems.

Any requirement that exceeds previous qualification test data shall be presented to the NASA as part of the planning process for evaluation and a possible delta qualification test.

The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method, set up, instrumentation, and data analysis methods, and give the sequence of the tests.

The plan shall include a verification matrix summarizing how all requirements in the specification are verified (analysis, inspection, test, per the definitions below) and listing all tests that will be performed on the thruster.

This plan shall be a contractor-controlled document and indicate all changes made after the initial approval by the NASA. After Verification Plan approval, no changes shall be made without written NASA approval.

If any individual test plans are created in addition to the master Verification Plan, such as for Thermal Vacuum testing, those plans shall also be provided. (DIL #38)

5.3 VERIFICATION METHODS

Verification methods include inspection, analysis, as well as environmental, functional, and performance testing, or a combination of these techniques.

5.3.1 Inspection

Verification by inspection includes (but is not limited to) visual inspection, simple physical manipulation, gauging, measurement, and documentation examination.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

5.3.2 Analysis

Verification by analysis is used to show design margins. Also, when the particular tests required for verification are impractical, risky, unacceptably long, or prohibitively expensive, analysis may be used instead of testing, as noted in the verification matrices and approved by the NASA

COR.

Analysis, including simulations where applicable, is also used to guarantee that the thruster and its components will perform as expected under worst-case conditions.

5.3.3 Test

Verification by test includes, but is not limited to, the evaluation of performance by use of special equipment or instrumentation, simulation techniques, and the application of established principles and procedures to determine compliance with requirements.

5.4 INSPECTION REQUIREMENTS

Verification by inspection shall be by one of these three methods: 1) visual inspection of the physical component; 2) a physical measurement of a property of the component, or; 3) a documentation search demonstrating component hardware of an identical design have demonstrated fulfillment of a requirement (also known as Qualification by Similarity).

5.4.1 Visual Inspection

Visual inspection of the physical component shall be performed by a qualified inspector to certify that the component has the properties/configuration specified in the requirement.

5.4.2 Physical Measurement

Physical measurement of component property (i.e. mass, dimensions, etc.) shall be performed by a qualified inspector to demonstrate the component meets specific requirement.

5.4.3 Documentation Search

Verification of requirements based on similarity shall include supporting rationale and documentation and shall be approved by the NASA COR.

5.5 ANALYSIS REQUIREMENTS

Verification of performance or function through detailed analysis, using all applicable tools and techniques, is acceptable with NASA COR approval. Detailed descriptions of the minimum required analyses, as well as analysis requirements, are provided in the herein.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

5.6 TEST REQUIREMENTS

This Section provides general test requirements on how testing is to be performed in the process of verifying that the deliverable item meets its requirements.

a. Performance parameter measurements shall be taken to establish a baseline that can be used to assure that there are no data trends established in successive tests that indicate a degradation of performance trend within specification limits that could result in unacceptable performance in flight.

b. Any requirement that exceeds previous qualification test data shall be presented to the

NASA COR as part of the verification planning process described herein, for evaluation and a possible delta qualification test.

5.6.1 Definitions

The hardware definitions are reproduced here from Section 1.8 of GEVS (GSFC-STD-7000A).

Prototype Hardware: “Hardware of a new design; it is subject to a design qualification test program; it is not intended for flight.” The purpose of the tests on this hardware is to prove that a new design meets one or more of its design requirements. Qualification testing is performed at maximum expected flight levels plus a margin. Test durations are typically longer than for acceptance tests.

Protoflight Hardware: “Flight hardware of a new design; it is subject to a qualification test program that combines elements of prototype and flight acceptance verification; that is, the application of design qualification test levels and flight acceptance test durations.” The purpose of the test on this hardware is to prove that a new design meets one or more of its design requirements. Protoflight testing is performed at maximum expected flight levels plus a margin.

Test durations are typically the same as for acceptance tests.

Follow-On (Acceptance) Hardware: “Flight hardware built in accordance with a design that has been qualified either as prototype or as protoflight hardware; follow-on hardware is subject to a flight acceptance test program.” The purpose of the test on this hardware is to prove that a particular flight unit has been manufactured properly. The design has already been proven during a qualification or protoflight test program. Acceptance testing is performed at maximum expected flight levels.

5.6.2 Thermal Cycle Prior to Structural Testing

Thruster hardware made of composites or Thruster hardware with bonded joints shall undergo thermal cycling to hot and cold survival temperatures a minimum of five (5) cycles prior to structural testing. Bonded valve heaters, thermostats, thermistors, and any other secondary/tertiary bonds may be exempt with NASA COR approval.

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

5.6.3 Non-Destructive Examination

NDE of critical weldments (and/or other material joining’s) shall be performed pre- and post-proof test.

5.6.4 Verification Test Procedures

The contractor shall generate Verification Test Procedures (acceptance testing and qualification testing as applicable) and provide them to the NASA COR. (DIL #39)

The verification procedures shall be step-by-step instructions for performing tests outlined by the Verification Test Plan. The procedures shall define the environmental conditions for the tests, required equipment and facilities, test constraints, use of diagnostic or performance test software, operating conditions, tolerance on all input stimuli, data to be recorded and pass/fail limits.

Verification Test Procedures shall be contractor-controlled documents and indicate all changes made after the initial release for review to NASA.

5.6.5 Verification Test Reports

The contractor shall generate Verification Test Reports. (DIL #40) These reports shall document the results of each test that was performed, what test levels were achieved, what performance requirements were verified, what anomalies were seen, and how they were resolved.

5.6.6 Test Factors

The following test factors and durations, shown in Table 5-1, shall be used for prototype, protoflight, and follow-on flight hardware.

Table 5-1: Test Factors and Durations

Test Prototype Protoflight Acceptance Structural Loads

Level Duration

Centrifuge Sine Burst(1)

1.25 X Limit Load

1 Minute

5 Cycles Full Level

1.25 X Limit Load

30 Seconds

Limit Load(2)

30 Seconds

Random Vibration Level Duration

Limit Level +3dB

2 Minutes/Axis

Limit Level +3dB

1 Minute/Axis

Limit Level

1 Minute/Axis Sine Vibration

Level Sweep Rate(3)

1.25 X Limit Level

Octaves/Minute/Axis

1.25 X Limit Level

Octaves/Minute/Axis

Octaves/Minute/Axis

Shock Actual Device Simulated

2 Actuations

1.4 X Limit Level

2 Actuations/Axis

2 Actuations

1.4 X Limit Level

1 Actuations/Axis

1 Actuation

1 Actuation/Axis

Use or disclosure of data contained on this page is subject to the restriction(s) on the title page of this document.

(1) Sine burst testing shall be done a frequency sufficiently below primary resonance as to ensure rigid body motion.

(2) If qualified by analysis only, positive margins must be shown for factors of safety of 2.0 on yield and 2.6 on ultimate. Beryllium and composite materials cannot be qualified by analysis alone. Test levels for beryllium and composite structure, including metal matrix, are 1.25 x Limit Level for both qualification and acceptance testing..

(3) Unless otherwise specified these sine sweep rates shall apply.

5.6.7 Test Tolerances

Tolerances for the various mechanical test parameters are given in Table 5-2.

Table 5-2: Test Tolerances

Test Test Parameter Tolerance Temperature ± 2 °C Humidity ± 5% RH Loads Steady-State (Acceleration): ± 5% Static: ± 5% Mass Properties Weight: ± 25g Center of Gravity: ± 5 mm Moments of Inertia ± 5 % Products of Inertia ± 5 %

Mechanical

Response Spectrum:

Simulated (f ≤ 3kHz) Simulated (f ≥ 3kHz)

Shaker

± 6 dB

+9/-6 dB ± 3 dB

Shock Time History: ± 10% Pressure >1.3 x 104 Pa (> 100 mm Hg): ± 5%

1.3 x 104 to 1.3 x 102 Pa (100 mm Hg to 1 mm Hg): ± 10%

1.3 x 102 to 1.3 x 101 Pa (1 mm Hg to 1 micron): ± 25% < 1.3 x 101 Pa (< 1 micron): ± 80% Vibration Sinusoidal: Amplitude ± 10% Frequency ± 2%…