SMAAART TASK ORDER: SOW TASK TITLE: WELD REPAIR THERMAL AND STRUCTURAL ANALYSIS FOR THE MACH 5 HIGH DYNAMIC PRESSURE NOZZLE AT NASA LANGLEYS 8 HIGH TEMPERATURE TUNNEL 1.0 INTRODUCTION/BACKGROUND: THE 8 HIGH TEMPERATURE TUNNEL (HTT) AT NASA LANGLEY RESEARCH CENTER (LARC) IS A TRUE ENTHALPY, TRUE PRESSURE, BLOW-DOWN, HYPERSONIC TEST FACILITY THAT IS UTILIZED BY RESEARCH ENGINEERS TO PERFORM HYPERSONIC AEROTHERMODYNAMIC AND PROPULSION SYSTEM TESTING. THE FACILITY PROVIDES TEST CONDITIONS AT MACH 7, MACH 5, MACH 4, AND MACH 3. FOR TESTING AT EACH MACH NUMBER, SEPARATE CONVERGING-DIVERGING NOZZLES ARE REQUIRED TO BE INSTALLED. EACH FACILITY CUSTOMER SELECTS THEIR DESIRED TEST CONDITION AT THE NOMINAL MACH NUMBER AND THE FACILITY STAFF DETERMINES WHAT CONTROLLED CONDITIONS ARE REQUIRED TO MEET THE CUSTOMER S OBJECTIVES. ONE OF THE CONVERGING-DIVERGING NOZZLES AVAILABLE FOR USE BY THE FACILITY CUSTOMERS IS DESIGNATED THE MACH 5 HIGH DYNAMIC PRESSURE NOZZLE (M5HIQ). THIS NOZZLE WAS DESIGNED AND BUILT BY ATK UNDER NASA CONTRACT/TASK ORDER NNL05AA06B, NNL06AA60T. THIS NOZZLE IS REQUIRED TO CONDUCT MISSILE RADOME TESTING BY THE NAVAL AIR WARFARE CENTER AND IS ALSO REQUIRED FOR FUTURE TESTING OF HYPERSONIC ENGINES. RECENTLY, DAMAGE IN THE FORM OF A LARGE SURFACE CRACK WAS FOUND ON THE M5HIQ NOZZLE. THIS LARGE CRACKED HAS CAUSED THE FACILITY TO HALT TESTING OPERATIONS FOR THE NAVAL AIR WARFARE CENTER. BECAUSE THE NOZZLE IS SUBJECTED TO EXTREME TEMPERATURES DURING OPERATION, THE CRACK MUST BE REPAIRED PRIOR TO RESUMING TESTING OPERATION REQUIRING THAT PARTICULAR NOZZLE. NASA WILL CONTRACT THROUGH ITS FABRICATION DIVISION FOR THE WELD REPAIR OF THE NOZZLE CRACK ONCE THE THERMAL / STRUCTURAL ANALYSIS REQUIRED UNDER THIS SOW IS COMPLETED. THIS SOW ANALYSIS WILL REQUIRE RESEARCHING THE INCONEL 800H BASE METAL AND THE WELD FILLER METAL MATERIAL PROPERTIES AT ELEVATED TEMPERATURES AND PERFORMING THERMAL AND STRUCTURAL ANALYSIS OF THIS WELD JOINT TO ESTIMATE THE LOW CYCLE FATIQUE LIFE OF THE REPAIRED NOZZLE. THE WELD JOINT EXPERIENCES TRANSIENT MECHANICAL PRESSURE LOADING COUPLED WITH EXTREME THERMAL TRANSIENTS WHICH COMBINE TO MAKE THIS ANALYSIS COMPLEX. IN ADDITION, THE DATABASE FOR THESE MATERIALS ARE EXPECTED TO BE INCOMPLETE, SO TECHNICAL REASONING BASED ON THE BEST AVAILABLE DATA WILL BE REQUIRED TO COMPLETE THE EFFORT. THE ANALYSIS OF THE WELD JOINT IS REQUIRED TO MEET NASA SAFETY STANDARD LPR 1710.15. THE M5HIQ NOZZLE WAS ORIGINALLY DESIGNED BY ATK-GASL AND THEY POSSESS FEM GRIDS, TUNNEL OPERATING CONDITIONS, AND OTHER THERMAL AND STRUCTURAL ANALYSIS TOOLS THAT CAN BE UTILIZED TO EVALUATE THE WELD REPAIR LOW CYCLE FATIQUE LIFE. THIS ANALYSIS IS CRUCIAL TO THE SAFE RETURN TO TESTING OPERATIONS FOR THE NAVAL AIR WARFARE CENTER. 2.0 SCOPE/OBJECTIVES: THE SCOPE OF THIS TASK ORDER IS TO CONDUCT A THERMAL AND STRUCTURAL ANALYSIS OF THE REPAIR WELD JOINT LOCATED IN THE NASA LARC 8 HTT. THE OBJECTIVE(S) OF THIS TASK ORDER ARE TO: DELIVER A REPORT SHOWING THE LOW CYCLE FATIQUE LIFE FOR THE WELD REPAIR DEPICTED IN THE GOVERNMENT-FURNISHED DRAWING (GFI 5.1). 3.0 DESCRIPTION OF THE WORK/TASKS TO BE PERFORMED: THE CONTRACTOR SHALL PERFORM THE FOLLOWING TASKS: 3.1 THERMAL / STRUCTURAL ANALYSIS REPORT: 3.1.1 THE CONTRACTOR SHALL CALCULATE THE LOW CYCLE FATIGUE (LCF) LIFE OF THE NOZZLE USING THE GOVERNMENT FURNISHED DRAWING NASA LD-1268149 M5HIQ WELD REPAIR DRAWING (GFI 5.1) DEPICTING THE WELD REPAIR JOINT GEOMETRY. THE CONTRACTOR SHALL USE THE THERMAL AND STRUCTURAL LOADS FROM THE ORIGINAL NASA CONTRACT/TASK ORDER NNL05AA06B, NNL06AA60T. CONCURRENTLY, NASA WILL BE EXECUTING THE WELD REPAIR. THE CONTRACTOR SHALL CALCULATE THE LCF OF THE WELD REPAIR UNDER THE FOLLOWING TWO CONDITIONS: 3.1.1.1 NO NON-DESTRUCTIVE INSPECTION OF THE WELD JOINT IS CONDUCTED DURING THE WELDING. 3.1.1.2 100% X-RAY INSPECTION OF THE WELD JOINT IS CONDUCTED AFTER COMPLETION OF THE WELDING.