1. www.nasa.gov National Aeronautics and Space Administration Ares I-X Statement of Work (SOW) Overview Monica Hoffmann Industry Day 14 November 2007 Monica Hoffmann Industry Day 14 November 2007

2. 2 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Procurement Details  Three Commercial procurements planned  Procurement 1 – RFQ release on or about 11/16/07 – Parts- US-7, IS-1 and SA  Procurement 2 – RFQ release on or about 12/21/07 – Parts- IS-1 and US-1  Procurement 3 – RFQ release on or about 11/16/07 – Flange Face Machining  Approximately two weeks to submit proposals.  Fixed Price Contracts  Delivery incentives  1%/day award based on delivery.  Best Value Selection  Technical Quality = Meet Specifications + Schedule + Quality Assurance  Price  Past Performance  The government to provide:  All NASA specifications and documents  Weld wire material  Option for providing segment transportation cart.

3. 3 National Aeronautics and Space Administration Ares I-X Statement of Work Overview  Procurements 1 and 2:  Ballast Support Structure Parts  Protuberances:  RCS Covers OML (US-1)  Ullage Motors OML (US-1)  Camera OML (US-7)  UHF Antenna OML (US-7)  Simulated flange OML  Systems Tunnel OML  Liquid Hydrogen OML Ballast Segments US-7 and US-1

4. 4 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Protuberances

5. 5 National Aeronautics and Space Administration Ballast Segments US-7 and US-1 Ballast Support Structure Parts Overview

6. 6 National Aeronautics and Space Administration Ares I-X Statement of Work Overview  Service Module Segment  16.5 foot diameter  100 inches tall  approximate mass: 11,300 lbs  Procurements 2 and 3:  RCS thruster protuberances  SM Flange Face machining OML protuberances for RCS thrusters

7. 7 National Aeronautics and Space Administration Ares I-X Statement of Work Overview ECS Panel I-beam support structure; A36 Steel All Booster Deceleration Motors (BDMs), eliminated - moved to first stage. RoCS Doublers (welded to IS-1 skin) Cutout size: 52.56 high X 49.93in wide T STRINGER (3 pieces) www.nasa.gov Access Door and internal Access Door Doubler (welded to IS- 1 skin). ECS Panel IS-1 Floor (2 sections) Ladders (4) IS-1 Procurements 1, 2 and 3 Flange Face Machining 117” tall x 18’ diameter Approx. mass = 28,000lbs

8. 8 National Aeronautics and Space Administration IS-1 Access Hatch Assembly Welded halves 38 Self-locking nut plates, NASM21060-6W or –L6W

9. 9 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Spacecraft Adapter Conical Skin  Steel Grade A70, ½” thick skin  Rolled and welded  Conical Shape Skin-with diameter transition of18 ft (216.5”) to 16.5 ft (198 “)  114 inches tall  approximate mass = 13,000lbs

10. 10 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Requirements  The contractor shall develop a technical plan (schedule) laying out tasks, durations, and dates for task completion with their proposal/quote. Updates to the schedule shall be provided for changes affecting the deliverables.  The contractor shall provide a Quality Plan with their proposal.  The contractor shall machine the SM and IS-1 flange faces and provide the parts per SOW Appendix D Parts Summary and Delivery Schedule and the following requirements:  as specified on the NASA Drawings.  Free of nicks, cuts, scratches, burrs, dirt, grease and/or oil prior to delivery  Provide packing for the completed components to prevent any damage during all phases of manufacturing and handling, including transportation from the Contractor’s plant to NASA Glenn Research Center  The contractor shall mark the parts as follows:  The contractor shall identify all parts as specified on the NASA Drawings.  The contractor shall prepare and paint the components as required per Appendix D and as indicated on the drawing, on all surfaces in accordance with the SSPC SP6 preparation standard, a 2-3 layer (corrosion resistant primer and top coat as specified in the drawing at a minimum) paint system sufficient to withstand ~2 years use (GRC/KSC environment), and with FED-STD-595 and as specified on the NASA Drawings.

11. 11 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Requirements continued  The contractor shall prepare samples and submit inspection results of sample welds representing all Class A welds in accordance with ARES I-1-REQ-061, no later than 2 weeks prior to fabrication for government approval to proceed.  The contractor shall provide during fabrication the written weekly status based on their schedule electronically (email and/or Microsoft Word) including:  Status on the purchasing and delivery of the materials and commercial items; and status of obtaining any required permits.  Percentage of completion of the fabrication.  Brief summary of work completed during the week.  Any problems or concerns with suggested resolutions and potential delays in the Deliverable Items.  Non conformance to specified inspections; non conformances shall be also transmitted per verification requirements in SOW appendix A.  The contractor shall support the following plant visits by the government:  within two weeks after the award of the contract, to review inspection and fabrication facilities and Quality Assurance processes.  prior to final welding (at fit-up and tack phase) of parts with Class A welds.  During SM and IS-1 segment handling at the contractor facility.  Government inspections for part acceptance may take place at the contractor facility.

12. 12 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Verification Requirements  Inspection – Dimensional inspections of all hardware at the contractor’s site and in accordance with AMSE Y14.5M-1994 “Geometric Dimensioning and Tolerancing.  Full volumetric nondestructive examination (NDE) of critical welds to follow requirements of GRC-ARES I – 1-REQ-061.  All NDE reports are to be delivered to and reviewed by NASA GRC prior to acceptance of the component.  Any non-conformances and disposition/corrective actions developed in accordance with GRC-ARES I-1-REQ-061 shall be included in the weekly status submitted to the government. Any non- conformances that are not correctable in accordance with REQ-061, shall be reported to NASA, GRC for reporting and disposition through Ares I –X Material Review Board.

13. 13 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Quality Assurance Requirements  The contractor shall provide a quality plan with their proposal.  The contractor is not given Material Review Authority. All changes proposed by the contractor, as well as acceptance of any nonconforming product are at the discretion of the ARES-I-X project team alone.  NASA/GRC reserves the right to perform a Pre-award Survey at the contractor’s facility if deemed necessary.  NASA/GRC reserves the right to perform an on-site visit to review manufacturing operations and, or product status after notification of the contractor.  Acceptance shall be after verification of the finished product by NASA/GRC. This may be performed at the contractor’s facility prior to shipment to NASA/GRC, or at NASA GRC at NASA discretion.  For the purpose of this contract, any or all site visits may be performed by NASA or a NASA authorized third party contractor acting as NASA’s agent. If a NASA contractor is used, they shall be given the access to the contractor’s facility necessary to perform the function as required by NASA under this contract.

14. 14 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Flange Face Machining - Unique Requirements 1. Service Module Simulator:  a. Machine top flange and drill holes per drawing – 060213MFA701  b. Deliver CNC machine files for the flange bolt holes. 2. Interstage Simulator-1  Machine bottom flange per Drawing (TBD- to be made available January, 2008) as follows:  a. Flatness requirement :  The IS-1 bottom flange will be machined with a maximum out-of- flatness tolerance of 0.010” in the restrained condition. In addition, the machined flanges will have a local flatness tolerance of 0.005" over a 10º sector.  b. There will be 180 equally spaced holes, 120 will be for tension bolts and have a clearance hole.745 -.755 inches, the other 60 holes will be.000 -.005 inch clearance and.625 -.630 inch diameter on a 213.00 inch bolt circle.  c. Three alignment holes are required 1.120 - 1.130 in. diameter located on a 208 inch bolt circle at the 0°, 130°, and 230° positions.  d. Deliver: CNC machine files for the flange bolt holes.

15. 15 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Space Craft Adapter - Unique Requirements  1. As shown in NASA Drawing 060213MFA701, vendor shall quote only the rolled outer straight cone skin without the top and bottom flanges welded to the outer skin.  The vendor shall use the NASA Drawing 060213MFA931 for the weld prep of the outer straight cone skin welding and use NASA Drawing 060213MFA932 to prep the top and bottom edges of the outer skin. No gussets as shown in views “Detail E, F, G, and H shall be required.  Vendor shall fixture and/or brace the finished SA Assembly, so that during manufacturing, handling and shipping to NASA Glenn the SA Assembly shall conform to the dimensions as specified on the NASA Drawing.  All certification of conformance, inspection and NDT reports and weld documentation as specified on the drawings will be required.  The Vendor shall note the top diameter dimension of the SA Assembly as shown on NASA Drawing 060213MFA701 [198.00”] shall be changed to read, [198.125” – 197.875”]

16. 16 National Aeronautics and Space Administration Parts Procurement US-7 and IS-1 Delivery Schedule

17. 17 National Aeronautics and Space Administration SM and IS-1 Flange Face Machining Delivery Schedule DeliverablesDates) (on or before) Technical Plan / updatesInitial with proposal; updates with changes affecting deliverables Quality PlanWith proposal Segment Handling and Lifting PlanSM segment: With Proposal IS-1 segment: within 1 week of IS-1 drawing receipt. Permits as requiredPrior to Segment pickup from NASA GRC SM SimulatorDec 21, 2007 SM available at GRC Jan 11, 2008 SM complete - delivered to GRC SM CNC FilesWithin 1 week prior to shipment of corresponding unit IS-1 SimulatorMay 1, 2008 IS-1 available at GRC May 13, 2008 IS-1 complete- delivered to GRC IS-1 CNC FilesWithin 1 week prior to shipment of corresponding unit Final inspection results of partsWithin 1 week prior to shipment of corresponding unit StatusWeekly (Friday of each week) Note: All documentation deliverables shall be in Microsoft Word

18. 18 National Aeronautics and Space Administration What Happens after Today?  Government will revise SOW based on feedback / discussions / questions  Drawing package to be updated (some parts in draft may not be included in the final package; may include some new parts that were not in the draft SOW.)  Anticipate a final request for quote go out at the end of this week or early next week.  Proposals due back in approximately 2 weeks (11/29/07).  Anticipate award by 12/7/07.

19. www.nasa.gov National Aeronautics and Space Administration ARES I-X Industry Day Quality Requirements Tim Gaydos November 14, 2007 Tim Gaydos November 14, 2007

20. 20 National Aeronautics and Space Administration ARES I-X Quality Requirements  100% inspection with actuals recorded  No MRB authority – all nonconformances requiring repair or “use-as-is” disposition requires NASA approval  Material Traceability  Starts with purchasing  Certificate of Conformance – document signed by supplier affirming product meets relevant specifications  Manufacturer’s Test Report (MTR) – document produced by manufacturer certifying information required by applicable specifications. Usually includes lot number, manufacturing date, lot quantity, raw material heat number, chemical composition (actuals), and mechanical/metallurgical test results (actuals).  Government Furnished Material (GFM) – needs segregation and control  Traceability – documentation demonstrating solid chain from manufacturer through all distributors to buyer. Must be specific to lot/material purchased.

21. 21 National Aeronautics and Space Administration ARES I-X Quality Requirements Standard Quality Requirements  Independent quality function  Configuration Control – emphasis on control of customer changes and production process changes  Control of nonconforming material  Customer communication  Receiving inspection

22. 22 National Aeronautics and Space Administration ARES I-X Quality Requirements  Welding Requirements from ARES  Qualified Welders  Approved Welding Procedure Specifications traceable to an approved Procedure Qualification Record  Weld Inspection  NDE personnel shall certified per to NAS 410  Level II  Level III for approved inspection procedures  Certified Weld Inspector (CWI) per AWS QC1  Weld Inspections depend on weld Class  Class A welds require volumetric, surface (per layer) and visual inspections (per pass)

23. 23 National Aeronautics and Space Administration Ares I-X Statement of Work Overview BACKUP SLIDES

24. 24 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Parts Summary and Delivery Schedule

25. 25 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Parts Summary and Delivery Schedule

26. 26 National Aeronautics and Space Administration GFE  Dual Shield Certified FCAW Weld Wire, E71T-1M / E71T-12M  Each Spool weighting 33 lbs.  Wire diameter.045  Segment Cart may be provided  Approximately 12, 000 lbs;  27 inches tall and 18 ft diameter  Equipped with single- or dual-wheel casters, depending on the weight of the segment that will be mounted to it.  cart with single-wheel casters weight limit = 24,000 lb,  cart with dual-wheel casters weight limit = 48,000 lb.

27. 27 National Aeronautics and Space Administration Ares I-X Statement of Work Overview Quality Assurance Requirements  The contractor shall provide a quality plan detailing the processes and procedures that will be used in the performance of this procurement. If the contractor is ISO 9001 or AS9100 certified, the certification detailing approved operations should be included with the plan. The contractor may use existing Quality Plans/Quality Manual or procedures, as appropriate, already in place to meet this requirement. As a minimum, the plan shall address the following:  Configuration Management including control of customer changes  Nonconforming control, corrective and preventive actions  Material identification and traceability including Material Test Reports or Certificates of Conformance, as required.  Calibration control of measuring and test equipment including traceability of standards to the National Institute of Standards and Technology for applicable tolerances measuring 0.010” and smaller  Control of Government Furnished Material  Inspection planning  Initial Quality planning  Subcontractor controls  Receiving inspection  All final inspection shall be 100% and actual inspection results shall be recorded for each unit unless directed otherwise.  Special process procedures  Preservation, packaging, handling and shipping procedures  Training records of special processes certified employees