TLX DVT - SOW_v1.pdf

22 Feb 22

Attachment (I)

STATEMENT OF WORK

Detonating Cord Assembly (DCA) /

Thin Layer Explosive (TLX)

Second Source Project

Design Verification & Production Demonstration of New Shock Tube Material

1.0 Background

Detonating Cord Assemblies (DCA) or Thin Layer Explosive (TLX) components are designed to transmit a detonation signal from input action to output device in a wide variety of

DoD aircraft and weapon system applications. The Naval Surface Warfare Center, Indian Head

Division (NSWC IHD) requires a Design Verification Test (DVT) effort and a production demonstration effort for a proposed new DCA/TLX line configuration, including a series of Non-

Destructive Tests (NDT), and product certifications to support the evaluation of the proposed new DCA/TLX line configuration. The NDT for these lines includes dry gas leak tests and radiographic (X-ray) inspections.

With the Halar 700 no longer available to be utilized in the final configuration, a supplemental DVT program is needed to build confidence the new proposed shock tube material can withstand the environmental test requirements for the DCA/TLX lines. The Contractor shall design and produce new lines which will be evaluated for compliance with the technical requirements as presented in DCA Detail Specification (MIL-DTL-82889A dated 25 Mar 04).

The Contractor shall also perform a series of environmental and functional tests on the new lines.

The results of this study, in addition to the results of the previous NSWC IHD functional testing efforts, will be utilized to determine the reliability of this new configuration to function after exposure to various U.S. Navy, Air Force, Army aircraft operating environments.

2.0 Scope

The scope of this Statement of Work (SOW) defines the effort to be conducted by the

Contractor in support of the DCA/TLX Design Verification & Production Demonstration of New

Shock Tube Material.

The Contractor shall conduct an engineering study to verify the capability of two proposed High Energy (HE) shock tube material (HALAR 300DA and 350LC) and to demonstrate the production capability to manufacture this new HE component that could potentially achieve all of the operational requirements as presented in the DCA Detail

Specification (MIL-DTL-82889A dated 25 Mar 04). Based on the results of initial baseline testing, the Contractor shall provide a recommendation of one of the two shock tube materials to be utilized in the final item configuration. The Contractor shall incorporate the enhanced

DCA/TLX component design, utilizing the selected shock tube material and production manufacturing process, and fabricate twenty four (24) prototype DCA/TLX HE component lines and conduct a series of environmental and functional tests on the lines.

3.0 Applicable Documents

DI-MGMT-80555A Program Progress Reports

DI-MISC-80771A Scientific and Technical Reports

MIL-DTL-82889A Detonating Cord Assembly (DCA)

ASTM E1742 Standard Practice for Radiographic Examination

STANAG 4147 Chemical Compatibility of Ammunition Components with

Explosives

844AS292 Union, Inert Connector (SMDC)

841AS803 Dent Block

3.1 CONTROLLED UNCLASSIFIED INFORMATION (INCLUDES FOR OFFICIAL

USE ONLY INFORMATION)

Contractor may be required to handle Controlled Unclassified Information (CUI). There are numerous types of CUI, e.g. documents with limited distribution statements, documents marked as For Official Use Only (FOUO), etc. The minimum level of protection for all CUI is adherence to FOUO protection standards. Distribution Statements (DS) and warning labels, such as the Arms

Export Control Act Warning, identify additional protection requirements for a given document. Minimum FOUO protection requirements/controls applicable to the performance of this contract for CUI are listed below. Additional protection requirements, as marked on a given

CUI document, are in addition to the standards listed.

3.1.1. Handling/Storage: Access to FOUO is limited to those needing it to conduct official business for the Department of Defense (DoD). FOUO information is not classified information, but requires extra precautions to ensure it is not released to the public. During business hours, reasonable steps shall be taken to minimize risk of access by unauthorized personnel. After business hours, FOUO information shall be stored in unlocked containers, desks, or cabinets if

Government or Government-contracted building security is provided. If it is not, store in locked desks, file cabinets, bookcases, locked rooms, or similar items.

3.1.2. Transporting/Transmitting/Release/Destruction: FOUO information shall be transported in a manner that prevents disclosure of the contents. FOUO information may be sent via USPS first-class mail, parcel post, or – for bulk shipments – 4th class mail. Electronic transmission of FOUO information (voice, data, or facsimile) shall be by approved secure communications systems. Transmission via unsecure fax is acceptable if an authorized person is standing by on the receiving end to take custody. All emails containing FOUO or attachments with FOUO must be digitally signed and encrypted when transmitted within a Navy network or to an approved Contractor email address. Transmission of FOUO (i.e. any CUI) to personal email

Attachment (I) accounts (e.g. AOL, Yahoo, Hotmail, Comcast, etc.) is strictly prohibited. FOUO sent out of the Contractor’s facility electronically must be encrypted (DoD FIPS 140-2 standard). FOUO material shall not be released outside the Contractor’s facility except to representatives of DoD. When no longer needed, destroy FOUO by a method that precludes its disclosure to unauthorized individuals.

3.1.3. Markings: Unclassified documents (paper or electronic) generated in support of this contract which contain FOUO are to be marked “For Official Use Only” at the bottom on the outside of the front cover (if any), on each page containing FOUO information, and on the outside of the back cover (if any). Each paragraph containing FOUO information shall be marked as such. Within a classified document, an individual page with both FOUO and classified information shall be marked at the top and bottom with the highest security classification of information appearing on the page. Individual paragraphs shall be marked at the appropriate classification level, as well as unclassified or FOUO, as appropriate. Within a classified document, an individual page that contains FOUO information but no classified information shall be marked

“For Official Use Only” at the top and bottom of the page, as well as each paragraph that contains

FOUO information. Other records, such as photographs, films, tapes, or slides, shall be marked

“For Official Use Only” or “FOUO” in a manner that ensures that a recipient or viewer is aware of the status of the information therein. DS on technical documents identify access restrictions. DS “B” through “D” preclude public release and while not marked as FOUO, are subject to all FOUO protection requirements, including the prohibition on unencrypted transmission over the public Internet.

4.0 Requirements

4.1 The Contractor shall submit Program Progress Reports (Monthly Reports) every thirty (30) days after contract award date CDRL A001. The Contractor shall conduct a conference call twice per month.

The Contractor shall submit the Scientific and Technical Final Report upon completion of the work per CDRL A002.

4.2 The Contractor shall design and develop a High Energy (HE) component configuration using two different shock tube materials (HALAR 300DA and 350LC) that can achieve all of the requirements in the current DCA Detail Specification. The Contractor shall document this proposed HE component design in accordance with their internal engineering procedures. They shall also certify all inspections of all of their manufactured DCA lines.

4.3 The Contractor shall develop a pedigree for their proposed HE component design utilizing a series of functional tests to be conducted at their facility with CAD/PAD technical team participation.

4.4 The Contractor shall develop production processes or manufacturing instructions to ensure that the proposed HE component design can be safely and reliably assembled at the

Brownsville, TX facility.

Attachment (I)

4.5 The Contractor shall conduct a pre-Production Readiness Review for their proposed

HE component design, with participation by NSWC IHD representatives, to review the production processes and manufacturing instructions.

4.6 The Contractor shall utilize this proposed HE component design and production processes to assemble twenty four (24) complete 47.5” DCA lines as indicated in Table I.

4.7 The Contractor shall certify that these newly fabricated lines were assembled in accordance with the Contractor’s manufacturing instructions.

4.8 The Contractor shall conduct an internal Test Readiness Review (TRR) at their facility at least one (1) week prior to testing. The Contractor shall present to the Government a review of the environmental test procedure, test setups, the list of equipment and instruments to be used in the tests, and their calibration. The Government will participate during the TRR.

4.9 The Contractor shall manufacture sufficient quantities of Unions in accordance with drawing 844AS492 and Dent Blocks in accordance with 841AS803 to conduct all testing required for this contract. The Contractor shall supply all other parts, materials, equipment, and facilities to conduct the testing per a Design Verification Test Plan to also include non-destructive tests x-ray and leakage. The test plan shall be submitted to the Government in accordance with CDRL A003 for review and approval.

4.10 Four (4) of each HALAR tube material shall be subjected to baseline testing in accordance with Tables 1 and 2. Once completed, one of the HALAR tube materials shall be chosen with participation by NSWC IHD representatives to conduct the remaining environmental tests. The Contractor shall then conduct a series of environmental and functional tests (in accordance with MIL-DTL-82889A, Union Dwg. 844AS292, Dent Block Dwg.

841AS803, and Tables 1 and 2) on twenty four (24) lines. All test results shall be submitted in the final report (CDRL A002).

Environment Rationale

Groups 1

(300DA)

(350LC)

3 (Chosen

HALAR)

Total Quantity 4 4 16

X-ray 4 4 16 See pre environmental condition

Baseline 4 4 Record Function Time & Indent

Vibration

NACES regime. Demonstrate withstand environments. Test across temperature range range

Shock

NACES regime. Demonstrate withstand environments. Test across temperature

Temperature

Cycling

DCAs will be subjected to 100 cycles (50 each at -65° F and

Attachment (I)

350° F) iaw MIL-DTL-82889A, Para. 4.6.4

Pressure

Cycling

DCAs will be subjected to 100 cycles from -65° F to 350° F iaw

MIL-DTL-82889A, Para. 4.6.5

Post X-ray 0 0 4 12 0 0 See post environmental condition

Functional Tests (See Matrix below)

-65 °F 2 2 2 2 2 2

200 °F 2 2 2 2 2 2

Table 1: DVT Test Matrix Note: All lines will be 49.27” long.

Test # Line Length (ft.) / Exposure Temp. (° F) Configuration

1 Baseline (300DA) -65 Test Tip → Dent Block

2 Baseline (300DA) 200 Test Tip → Dent Block

3 Baseline (300DA) -65 Test Tip → Dent Block

4 Baseline (300DA) 200 Test Tip → Dent Block

5 Baseline (350LC) -65 Test Tip → Dent Block

6 Baseline (350LC) 200 Test Tip → Dent Block

7 Baseline (350LC) -65 Test Tip → Dent Block

8 Baseline (350LC) 200 Test Tip → Dent Block

9 Compatibility (Post Vibration) 200 Test Tip→4’→Union→4’→Dent Block

10 Compatibility (Post Vibration) -65 Test Tip→4’→Union→4’→Dent Block

11 Compatibility (Post Shock) 200 Test Tip→4’→Union→4’→Dent Block

12 Compatibility (Post Shock) -65 Test Tip→4’→Union→4’→Dent Block

13 Compatibility (Post Temperature Cycling) 200 Test Tip→4’→Union→4’→Dent Block

14 Compatibility (Post Temperature Cycling) -65 Test Tip→4’→Union→4’→Dent Block

15 Compatibility (Post Pressure Cycling) 200 Test Tip→4’→Union→4’→Dent Block

16 Compatibility (Post Pressure Cycling) -65 Test Tip→4’→Union→4’→Dent Block

Table 2: Specific Test Conditions and Configurations

Note: Function times will be recorded for all tests

4.11 The energetic materials shall be compatible with each other and materials they may come into contact. The Contractor shall evaluate the compatibility of the energetic materials with each other and materials they may come in contact with by conducting compatibility testing using two separate methodologies per STANAG 4147, 2nd edition. Any dynamic work, including calibration, shall be done at 2°C/min. Provide the results of the tests to the Navy using the templates in STANAG 4147 for each method. Chemical Analysis (Test 5) shall not be used.

If the material is a pyrotechnic, the Vacuum Stability Test (Test 1) shall not be used, since pyrotechnics do not appreciably out-gas. At the conclusion of the compatibility testing the

Contractor shall submit a Chemical Compatibility Report to the Government for review and approval. Data and analysis report shall be submitted in the monthly report (CDRL A001).

Attachment (I)

Samples of all energetic materials and samples of the cord (shock tube) shall be delivered to NSWC IHD.

5.0 Deliverables

5.1 The Contractor shall submit Monthly Reports detailing their efforts over each thirty

(30) day period after contract award date. (CDRL A001). Included in these Monthly Reports, the Contractor shall submit all design or configuration changes, and results of environmental and functional test used to establish product pedigree. Also included in these Monthly Reports, the

Contractor shall submit the pre-Production Readiness review minutes, the results of environmental and functional testing (paragraph 4.10), and compatibility data and analysis

(paragraph 4.11).

5.2 The Contractor shall deliver a sample of the cord (shock tube). They should include 2 inert cords each of the Halar 300DA and Halar 350LC, as well as 3 loaded cords of each the

Halar 300DA and 350LC. The sample cord should be 8” in length. These samples shall be delivered to Phoenix, LLC at the address provided. The Contractor shall also deliver samples of each shock tube material with the energetics used in the tube for compatibility testing to Indian

Head at the address provided

Delivery address:

Phoenix, LLC

5115 Lacy Rd

Fitchburg, WI 53711

N00174 Explosives Scales Facility

5021 Safe Haven Way

Indian Head, MD 20640-5173

5.3 The Contractor shall submit a draft Final Report (CDRL A002) to the NSWC IHD team no later than 30 days after the completion of Task 4.10. The NSWC IHD team will review and comment on the Contractor’s Final Report no more than 30 days after submission.

5.4 The Contractor shall submit a Design Verification Test plan per CDRL A003

5.5 The Contractor shall submit a Final Report 30 days after NSWC comments are received.

5.6 The Contractor shall submit a Certificate of Compliance per CDRL A004, to certify that the lines were assembled in accordance with the Contractor’s inspections and manufacturing instructions prior to start of testing.

6.0 Operations Security

6.1 For Official Use Only (FOUO) Information and Controlled Unclassified Information

(CUI).

The Contractor shall be capable of accessing, handling, receiving and storing UNCLASSIFIED documents, equipment, hardware, and test items using the applicable standards of FOUO

Information.

6.1.1 Physical Security Standards for Sensitive Items. The Contractor shall provide property storage and accountability of sensitive conventional Arms, Ammunition, and Explosive

(AA&E). These standards are set forth in Department of Defense (DoD) 5100.76-M entitled

“Physical Security of Sensitive Conventional Arms, Ammunition, and Explosives.” The

Contractor facility storing or handling AA&E shall pass a pre-award Physical Security

Inspection of the facility.

6.1.2 Transportation Security Requirements: Supplies procured or furnished under this contract/subcontract, which are qualified as sensitive in accordance with Department of Defense

(DoD) 5100.76-M “Physical Security of Sensitive Conventional Arms, Ammunition, and

Explosives), or are shipped as DOT Hazard Class I Explosives 1.4C require special

Transportation Protective Service (TPS) during shipment from all points of origin to all destinations. TPS will be equivalent to the DOD security standard for the applicable sensitive category or explosive class identified under DOD 5100.76-M and DOD 4500.9R, Defense

Transportation Regulation, parts II and III, as added to or amended by applicable military service policies in accordance with guidance provided by Defense Logistics Agency (DLA)/Defense

Contract Management Agency (DCMA). Shipper’s Defense Contract Management District/Area

Operations (DCMD/DCMAO) transportation offices will furnish assistance in providing the sensitive category of items to be shipped, determining the TPS required, and obtaining the TPS from commercial carriers as necessary.

7.0 Technical Point of Contact:

Name: Mr. Bobby Abraham

Phone: (301) 744-2303

Email: Bobby.abraham@navy.mil mailto:Bobby.abraham@navy.mil