B08 - Attachment 01 - REVISED PWS_ROBOTIC WELD CELL.pdf

REV03

Performance Work Statement (PWS) for Robotic Weld Cell April, 25 2023

Preface: The Crane Army Ammunition Activity (CAAA) has a new requirement to manufacturer M825A1 155MM Smoke, WP rounds. In order to manufacture M825 rounds CAAA will require two Robotic Weld Cells to produce a minimum of 120 assemblies per 10-hour shift. Assemblies to be produced referenced in dwg# 15-12-267, dwg# 15-12-263, and dwg# 15-12-265. One Mig cell for welding the canister assembly referenced in dwg# 15-12-267 consisting of dual capability of process. Cell will include two Mig welding locations for redundancy/dual operations . One Tig cell for welding of the burster housing referenced in dwg# 15-12-263/265 consisting of dual capability of process. Cell will include two Tig welding locations in the cell for redundancy/dual operations. Both systems shall be turnkey with full robot programming and process fixturing. For repeatability and ergonomic reasons both weld cells shall be robotic based automated weld cells with the capability to load unwelded parts while robots are welding part assemblies.

REQUIREMENTS:

(1) Dual Zone Medium/Large Part Robotic Application Mig Weld Cell:

Robotic Welding Cell shall weld medium/large size parts (minimum length of 22” x 5” in diameter) and be capable of reorientation to access all welds. Dual Zone configuration is required for redundant operations with the capability of operating with a single cell if required due to system failure. Dual zone cell(s) shall be an engineered system capable of meeting the requirements listed in the weld cell requirements.

• Dual Zone Medium/Large Part Robotic Weld Cell shall meet welding requirements per

Drawing #15-12-267. Canister welds shall meet weld standard AWS D17.1/D17.1M, CLASS A. Weld filler material shall be ER70S-2. No operator interaction shall be required to flip and/or rotate part for weld application. Fixturing and weld application shall be designed for high heat and prolonged wear and tear.

(2) Dual Zone Small/Medium Part Robotic Application Tig Weld Cell:

Robotic Welding Cell shall weld small/medium parts (minimum length of 20” x .450” to 5” in diameter) and be capable of reorientation to access all welds, a Dual Zone configuration is required for redundant operations with the capability of operating with a single cell if required due to system failure. The dual zone cell(s) shall be an engineered system capable of meeting the requirements listed in the weld cell requirements.

• The Dual Zone Small/Medium Part Weld Cell shall meet welding requirements per

Drawing #15-12-265 Front Plate Assy and Drawing 15-12-263 Burster Well welds.

Burster welds shall meet weld standard AWS D17.1/17.1M, CLASS A. Weld filler material shall be ER70S-2. Pre-heat of front plate, tube, and plug components is REQUIRED, and shall be pre-heated to 300 deg F per dwg# 15-12-265, note 4. The robotic process shall supply, check, and verify pre-heat condition before application of weld. Post weld normalization/stress relief shall be performed to both end plug and front plate. Stress relief at 800 deg F for one hour in a furnace or 1000 deg F for five minutes using inductive coil shall be required. Stress relief shall insure hardness of the weld deposit and heat affected zone complies within 400 HV1kg maximum. No operator interaction shall be required to flip part and/or rotate part for weld of plate to tube, and tube to plug. Fixturing and weld application shall be designed for continuous operation, high heat, and prolonged wear and tear/industrial use.

(3) Weld Cell Requirements for both weld cells

• The system provided shall be ‘turn-key’, including, but not limited to, weld cell, machine setup, all necessary tooling and fixturing. All handling/fixturing shall not cause metal defects including dents, deformations, cracks, chips, scratches or tears.

• The weld fume collection system shall consist of a dual modular fume hood to fit the work cell surround enclosure and shall include mounting legs with floor pads, light kits to provide ambient light inside the work cell. The vendor shall install hose/duct connection from the fan to the filter and manual damper. The bag house collection system shall be a unit that can be placed in an inside/outside environment.

• Both systems shall be equipped with pull across/up/down screen in front of welding station to provide extra visual protection to the operators and restrict entry into weld cell while in operation.

• The system shall have a single “cycle start” button that can be initiated to start an automatic ‘production’ cycle. This ‘cycle start’ button shall be in close proximity to the weld system.

• Design for 85% Efficiency, maximum cycle time 2 minutes 10 seconds at 22” per minute per completed part (Dual Zone Medium/Large Part Robotic Application Weld Cell /Canister operation includes application of both front plate and rear plate welds. Dual Zone Small/Medium Part Robotic Application Weld Cell /Burster operation includes front plate to burster tube, and burster tube to plug.)

• Each weld cell shall be capable of operation at 100% duty cycle.

• Each system shall be installed at CAAA and fully functional within 45-days after receipt at Crane.

• Supply air (if required) will be provided within 15ft of equipment by the US government. Air requirement shall be communicated to the Government 45-days prior to equipment installation.

• Electrical power will be provided by US government from government’s building supply to a separate disconnect or directly to equipment’s power panel only. All other ancillary field electrical wiring, to include, but not limited to, push buttons, sensors, Tig stray current protection, and limit switches shall be provided by the contractor. Supply electrical requirements shall be provided to the government 45-days prior to equipment installation.

• The welding systems shall be equipped with an E-Stop button which stops weld process and robot function.

• The welding systems shall have high performance, advanced welding process, and highly efficient inverter power sources designed for industrial robotic weld operations with production monitoring technology.

• The weld systems shall have rugged reliable liquid cooled torches rated to 500 amps and designed to be integrated directly with power sources. The torch shall be designed to optimize clearance for tough to reach welding applications and shall have electrical conductivity through full face contact as opposed to rotating connections that have single line contact. The systems shall have a robotic torch maintenance system including reamer, antispatter application, and pneumatic wire clipper.

• The weld systems shall have automatic wire feed systems rated for MIG, Pulsed, surface tension transfer, and Flux-cored and Metal-cored wires and shall include robotic mounting bracket and consistently pull wire to maximize robotic acceleration performance and throughput.

• The weld systems and robotic interface shall have multi-group motion allowing interaction with auxiliary motors and index one location at a time, have capability of allowing two or more motion groups to index continuously, touch sensing and multipath capability and shall have capability of DCS, (“Dual Check Safety”), position and speed check detection for position and speed errors with self-diagnoses of safety hardware/software which does not require any external sensors.

• The weld systems shall be EMI shielded

• The weld systems shall provide a method to improve control over welding arc energy distribution across the weld by synchronizing weld schedules with torch weave position, improve process tolerance to weld joint fit-up variation, control weld bead profile, and accommodate differential heat sink due to weld joint asymmetry.

• The weld system hardware package shall be designed to work with touch sensing software using a series of high-speed laser touch routines to find locations, weld piece, and capability of saving locations into memory and the ability to shift or offset the welding program with laser location sensing.

• Training on system, operation, preventative maintenance, and setup shall be provided.

(4) Weld Systems End Item Acceptance Testing

• Acceptance Testing of System 1, Canister Weld:

a. To be completed by vendor, acceptance testing to be done by CAAA. The welding process shall be qualified per AWS D17.1/D17.1M and submitted to Crane Army Ammunition Activity for approval.

b. Metallographic Examination (drawing 15-12-267): To be completed by vendor, accepted by CAAA. As part of weld qualification, a quantity of 5 canister welds per qualified welding machine in operation for both canister welds (to end plug and to front plate) shall be prepared in accordance with ASTM E340. Two sectioned specimens per part shall be sectioned 180° apart, each sectioned specimen shall contain the weld and entire heat affected zone. A quantity of 10 sectioned specimens shall be examined using 5X and 100X magnification and shall meet the applicable requirements in Section 5 of AWS D17.1. Failure of any specimen to meet the requirements specified in AWS D17.1 shall be cause for rejection

c. Bend testing (drawing 15-12-267): To be completed by vendor, accepted by CAAA. As part of weld qualification, a quantity of 5 for both canister welds (to end plug and to front plate) per qualified welding machine in operation shall be prepared and examined in accordance with AWS D17.1. Two sectioned specimens per part shall be sectioned 180° apart and shall contain the weld and entire heat affected zone to be tested. Failure of any sectioned specimen to meet the requirements listed in AWS D17.1 shall be cause for rejection

d. Leak test Canister (Drawing 15-12-267): To be performed by CAAA prior to acceptance. The canister shall not leak when subjected to an internal air pressure of 75 psig minimum at ambient temperature when testing Canister (Drawing 15-12-267). The canister assembly shall be cleaned and dried prior to performing this test. The canister shall be assembled into a fixture which will permit the use of clean, dry air to internally pressurize the canister to the specified pressure and allow the canister to be submerged under water. The fixture shall be designed to pressurize the canister through the 3/4 inch hole in the rear plate. The fixture shall also be designed to allow any bubbles that form in the burster well to escape. The front plate end of the canister shall be elevated a minimum of 4 inches above the rear plate during this test. The pressure shall be maintained for a minimum of 15 seconds while the canister is submerged. The formation of bubbles indicates leakage. Note: A wetting agent shall be used in the leak test water to reduce surface tension.

e. Parallelism (drawing 15-12-267) of end plates: To be performed by CAAA prior to acceptance. Parallelism shall be maintained up to ½” from edge of plate (.030” over length of canister).

f. Hydrostatic Pressure test (drawing 15-12-267): To be performed by CAAA prior to acceptance. Canister shall withstand an internal hydrostatic pressure of 650 psi without bursting (destructive test, bulging is permitted). The canister shall be assembled into a test fixture and subjected to the specified hydrostatic pressure for a minimum of 10 seconds after which time the pressure shall be increased until the canister ruptures. The pressure at which the canister ruptured shall be recorded.

• Acceptance Testing of System 2, Burster Well Weld:

* Note: Before weld testing, stress relief of the Burster Well to the Front Plate and

End Plug Weld shall be performed within 4 hours of weld application. Inductance or furnace stress relief shall produce a maximum 400 HV1kg (Vickers micro-hardness) in the weld deposit and surrounding heat-affected zone. Peak temperature shall not exceed the lower austenite transformation temperature.

A temperature of 1,000 deg F for five minutes by means of inductance coil (OR) 800 deg F for 1 hour by means of furnace. Verification of time and temperature report are required to be provided to CAAA from the vendor.

a. The welding process shall be qualified by vendor per AWS D17.1/D17.1M and submitted to Crane Army Ammunition Activity for approval.

b. Metallographic Examination (drawing 15-12-263 and 15-12-265): To be completed by vendor, accepted by CAAA. As part of weld qualification, the quantities of burster welds specified in Tables I and II per qualified welding machine in operation for both burster tube welds (to end plug and to front plate) shall be prepared in accordance with ASTM E340. Two sectioned specimens per part shall be sectioned 180° apart and shall contain the weld and entire heat affected zone. A quantity of 10 specimens shall be examined using 5X and 100X magnification and shall meet the applicable requirements in Section 5 and Table 7.1 of AWS D17.1. Failure of any specimen to meet the requirements specified in AWS D17.1 shall be cause for rejection.

c. Bend Testing (drawing 15-12-263, 15-12-265): To be completed by vendor, accepted by CAAA. As part of weld qualification, the quantities specified in Tables I and II for both burster tube welds (to end plug and to front plate) per qualified welding machine shall be prepared and examined in accordance with AWS D17.1. Two welded specimens per part shall be sectioned 180° apart and shall contain the weld and entire heat affected zone to be tested. Failure of any specimen to meet the requirements listed in AWS D17.1 shall be cause for rejection

d. Micro hardness (drawings15-12-263, 15-12-265): To be completed by vendor, accepted by CAAA. As part of weld qualification, micro hardness shall be tested in accordance with ASTM E384. From the burster well to end plug (after stress relief), burster well to front plate (after stress relief) two micro hardness specimens per burster well shall be sectioned 180° apart and shall contain the weld and entire heat affected zone to be tested. A minimum of twenty indents shall be taken from unaffected base metal through heat affected zone and weld metal to unaffected base metal on other side of weld. Results from each indent shall be recorded for each sample tested. The micro hardness for the burster well to end plug and for the burster well to front plate shall be less than 400 HV1kg maximum. Failure of any specimen to meet the requirements listed in AWS D17.1 shall be cause for rejection.

e. Non-destructive Burster Well Tube Load Test (Drawing 15-12-265): To be performed by CAAA prior to acceptance. All welded assemblies per qualified welding machine in operation shall be subjected to this load test. Post-weld and stress relieved assemblies shall be loaded to 3,300 +/- 50 pounds. Before and after each test, measure and record the overall length to the nearest 0.01-inch. Insert a nominal 19-inch long, hardened steel mandrel into the burster well. Place a suitable tube over the burster well so that the tube end rests on top of front plate. Load assembly into test frame equipped with load cell calibrated to ASTM E4. Apply the 3,300 +/- 50 pound load. Upon completion of the test, the assembly shall be examined using 3x magnification minimum for any evidence of deformation, cracks, tears, and any other damage. If the overall length increases more than 0.05-inch as a result of 3,300 pound test, then the part shall be rejected per drawing 15-12-265 note 8.

f. Destructive Burster Well Tube and Front Plate Load Test (Drawing 15-12-265):

To be performed by CAAA prior to acceptance. After stress relief, the front plate assembly shall be subjected to a peak load tension test. Insert a mandrel or pin into the end of burster well tube to avoid crushing the tube when gripping the outer diameter with collet or other means. Support the front plate perpendicular to the pull direction then apply a tensile load at a rate of 0.05 inches per minute and pull to failure. Failure of either the burster well tube or the welded joint below 5,000 pounds is cause for rejection per drawing 15-12- 265 note 10.

(5) Weld Systems Final Acceptance:

• Each welding cell and produced assemblies shall have a qualified welding procedure satisfying the requirements listed on Drawings 15-12-263, 15-12-265, and 15-12-267 and in accordance with AWS D17.1/D17.1M. Prior to production of the qualification testing samples, as referenced below, the welding procedure and supporting test results shall be submitted to the contracting officer representative at Crane Army Ammunition Activity for approval. In addition, a final acceptance of 10 destructively tested Canister Assemblies, to be completed by CAAA, shall be tested for conformance and approval to Drawings 15-12-263, 15-12-265, and 15-

12-267 and in accordance with AWS D17.1/D17.1M before acceptance of welding systems. A welding machine shall be considered accepted/qualified after passing all 10 destructive samples and 30 consecutive non-destructive samples per section 4 of this DFP. Testing to be completed by CAAA.

*Crane Army Ammunition Activity will supply metal parts for Canister Assembly Qualification testing, for quantity 10 destructive and 30 consecutive non-destructive samples.

(6) Installation:

• The awardee shall notify the Government 45 calendar days prior to installation, of any utility or obstacles needing removed or redirected. These items include air lines, electrical lines/conduit, overhead lighting and fire suppression lines. Site visit required for determination of space allocation and utility supply requirements and location.

(7) Onsite validation:

• to be completed at CAAA

(8) Programming:

• Onsite weld cell programming/parameter settings to be completed at CAAA by the vendor.

(9) Delivery:

• Delivery to be made 12 weeks after award. Delivery shall be made Monday through Thursday between the hours of 0600-1300 EST. Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05/AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

Antiterrorism/Operations Security

(1) Access and general protection/security policy and procedures. Contractor and all associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Provost Marshal Office, Director of Emergency Services, or Security Office.

Contractor workforce must comply with all personal identity verification requirements (CFR clause 52.204-9, Personal Identity Verification of Contract Personnel) as directed by DoD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

(2) For contractors that do not require CAC, but require access to a DoD facility or installation. Contractor and all associated subcontractor employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (Army Directive 2014-05/AR 190-13); applicable installation, facility and area commander installation and facility access and local security policies and procedures (provided by Government representative); or, at OCONUS locations, in accordance with status-of-forces agreements and other theater regulations.