Characterization and Fatigue and Tensile Testing of Additive JBK-75 Alloy

Statement of Work (SOW) for Characterization and Fatigue and Tensile Testing of Additive JBK-75 Alloy supporting Additively Manufactured Handbook The National Aeronautics and Space Administration (NASA) Space Launch System (SLS) Liquid Engines Office (LEO) and Space Technology Mission Directorate (STMD) continues to foster public-private partnerships with industry and academia. In support of STMD, NASA is partnering with to advance additive manufacturing (AM) technologies. This collaboration focuses on new AM material development, characterization, data dissemination, and process capabilities, including surface enhancements and in-situ monitoring for AM materials specifically some industry specific alloys for liquid rocket engines. This SOW aims to complete all documentation, reporting, and data dissemination for AM alloy characterization initiated under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Optimized and Repeatable Component using Additive (ORCA), AM for Propulsion, and SLS LEO projects. The work will support NASA-led technology development projects, particularly in aerospace applications such as liquid rocket propulsion systems and large-scale space exploration structures. The tasks are as follows: 1. Characterization and Data Analysis: The contractor shall complete detailed characterization and analysis of mechanical test data from additively manufactured samples provided. 2. Literature Review: The contractor shall conduct a literature review and summary for each alloy listed in Table 1. Please note some of these are new alloys and may not have any public information available. 3. Data Summary and Documentation: The contractor shall summarize, analyze, and document all mechanical test and characterization results. 4. Initial Characterization: The contractor shall perform initial characterization using techniques such as scanning electron microscopy (SEM), computer tomography (CT) scanning, and optical microscopy. Additional techniques such as microhardness, grain size evaluations, etching, and residual stress measurements shall be considered to enhance the dataset. 5. Thermal State Characterization: The contractor shall characterize materials in the as-built state and after each heat treatment stage, optimizing heat treatment as necessary. 6. Mechanical Testing: The contractor shall conduct room temperature and elevated temperature tensile and fatigue testing per the matrices below using the provided JBK-75 samples. All samples shall be appropriately sectioned or machined prior to testing per ASTM standards. Tensile Powder Re-use Samples (x8 reuses) Orientation Temp (F) # Samples Vertical 70 24 Vertical 1200 24 *supplied as boxes and samples shall be sectioned (EDM) -- 1 of 4 -- Fatigue Powder Re-use Samples (x8 reuses) Orientation Temp (F) # Samples Vertical, 2 strain cond per 70 48 Vertical, 2 strain cond per 1200 48 *supplied as boxes and samples shall be sectioned (EDM) Tensile Restart Samples Orientation / Condition Temp (F) # Samples Restart Vertical, 350W 70 3 Restart, Vertical, 1070W 1200 3 Restart Vertical, 350W 70 3 Restart, Vertical, 1070W 1200 3 Nominal Vertical, 350W 70 3 Nominal Vertical, 1070W 1200 3 dia to be machined Fatigue Restart Samples Orientation / Condition Temp (F) # Samples Restart Vertical, 350W 70 6 Restart, Vertical, 1070W 1200 6 Restart Vertical, 350W 70 6 Restart, Vertical, 1070W 1200 6 Nominal Vertical, 350W 70 6 Nominal Vertical, 1070W 1200 6 dia to be machined *Round samples shall be tested in HCF condition 6.1. The samples will be provided in the as-built surface condition but fully heat treated. Additional samples will be provided in the as-built condition. Low cycle fatigue (LCF) in strain control (or load control as discussed with the NASA contact) and high cycle fatigue (HCF) in load control shall be completed on samples to failure. 6.2. The flat powder reuse samples will be provided as harvest boxes with 4 panels from each box yielding about 5 specimens from each panel (total of 20 specimens). -- 2 of 4 -- 6.3. The restart study (build interruption) samples will be provided as round bars and full heat treated and shall be machined for tensile and fatigue. 6.4. The conditions will be agreed upon by NASA and contractor before testing is initiated. 6.5. Based on the test matrices, the total number of fatigue samples requiring sectioning and machining (as needed) is 132. The total number of tensile samples for sectioning and machining (as needed) is 66. 6.6. Contractor shall complete fatigue testing of (66) room temperature samples, (66) elevated temperature samples for the JBK-75 recycled powder study and restart study. 6.7. Contractor shall complete tensile testing of (33) room temperature samples, (33) elevated temperature samples for the JBK-75 recycled powder study and restart study. 7. Post-Mechanical Test Fractography: The contractor shall analyze postmortem tensile and fatigue specimens to determine failure mechanisms at various test temperatures. 8. Data Summary Sheet: The contractor shall provide a summary data sheet incorporating all tensile and fatigue test data, including any issues with data. 9. Organized Dataset: The contractor shall maintain an organized dataset in an accessible online database, including summary and raw test data and relevant post-test characterization data. 10. Collaboration with Test Service Companies: The contractor shall work with third-party test service companies to address testing questions and non-conformances. 11. Detailed Reporting: The contractor shall complete detailed reports in the form of NASA Technical Memorandum, journal articles, conference papers, or other publicly available reports for each alloy and task listed in Table 1, following approval by NASA export control. 12. Regular Meetings: The contractor shall attend bi-monthly meetings to discuss updates, results, and progress with NASA personnel. Additi…