Aviation Applied Technology Dir., ATTN: AMSAT-R-TC, Fort Eustis, VA 23604-5577

A -- R&D BROAD AGENCY ANNOUNCEMENT (PAGE 1 OF 2) SOL DAAJ02-97-R-0001 DUE 121396 POC Vickie L. Jordan, Contract Specialist, 757-878-4818. The Aviation Applied Technology Directorate (AATD) is soliciting technical and cost proposals for conduct of 6.2 Research & Development (R&D) programs. Proposals are required to be submitted in accordance with the guidelines set forth herein. This Broad Agency Announcement (BAA) constitutes the total solicitation. There will be no formal Request For Proposals, other solicitation requests, or other information regarding these requirements. Subject areas of interest include: TOPIC 01-97: Acoustic Fault Detection for Rotorcraft Transmission and Engines. TECHNICAL DESCRIPTION: Today's helicopter health monitoring systems are subject to false alarms. They result in mission aborts in the form of precautionary as well as forced landings. In addition, these conditions cause unnecessary maintenance including premature and incorrect removal of costly components. Acoustic monitoring of dynamic mechanical systems is a potentially viable technique to help accurately detect and isolate faults in these complex systems and to enhance operational safety. Acoustic emission monitoring methods are particularly applicable to bearing and gear fatigue failure detection. The higher frequency band is generally above ''normal'' vibration levels. These structure born ultrasonic frequencies generated by the fault can be stripped from background ''noise'' and digitally analyzed. Acoustic sensors when properly applied, processed and interpreted can be an effective means of measuring friction, shock and load transfers within and between oil wetted moving parts. Crack growth, spalled surfaces and material fretting are the physical manifestations of excessive wear of bearings and gears and early detection via acoustic monitoring can serve as an effective diagnosis of helicopter gearbox/engine health without intrusive maintenance inspections. Application of this technology to helicopter systems offers several challenging R&D opportunities. Very high data rates require advanced processing in order to achieve a real-time capability. Understanding the consequences of sensor design location and the sensitivity of these factors to signal quality and consistency is an important factor in system level design. The algorithms employed to analyze acoustic data are influenced by dependent variables such as torque and velocity and must be managed and accounted for in the processing function. Fault detection capability may be increased by using data fusion methods to localize the failure source and improve the diagnostic value. Good feature extraction and characterization inputs to a neural network or other pattern recognition scheme are critical to repeatable and confident diagnostic calls. In addition, the idea of further increasing processing speeds through the use of wavelet based features merits further development. The successful bidder(s) will be expected to address these technology needs in a balanced program. The program will include a data collection effort drawn from a ''bad'' dynamic component test. Research will be directed at those aspects of acoustic monitoring necessary to advance the technology to the point of a practical military application (emphasis on helicopters) with attendant applications possible in the commercial / industrial fields. The program will be scoped to include development of the fields of interest and a test conducted to validate or prove the diagnostic techniques. ANTICIPATED AMOUNT OF CONTRACT AWARD(S) (RANGE): $300k - $400k. ANTICIPATED PERFORMANCE PERIOD: Not to exceed 18 months (15 months for completion of technical and an additional 3 months for data submittal). TOPIC 02-97: Highly Loaded Airframe Fittings. TECHNICAL DESCRIPTION: Accurate prediction of stress distributions within primary load path components is difficult when multiple, highly transient loads are applied simultaneously. Failures occurring significantly below design ultimate load because of inaccurately predicted stress states are unacceptable. Improved modeling of structural details, material properties, and impact loads can result in more accurate design of airframe fittings that transmit impact loading to primary airframe structure for subsequent energy absorption. The purpose of this program is to design main landing gear-to- airframe fittings to sustain and transmit crash impact loads representative of 5.2 meter-per- second sink speeds from 0to 12pitch and roll. The offeror should analyze the selected configuration to assure that the load paths function as designed during dynamic load application. The offeror should validate the resultant design by limited impact testing with loads applied along a line of action representative of a main landing gear-to-fitting interface. ANTICIPATED AMOUNT OF CONTRACT AWARD(S) (RANGE): $500k - $600k. ANTICIPATED PERFORMANCE PERIOD: Not to exceed 32 months (29 months for completion of technical and an additional 3 months for data submittal). TOPIC 03-97: Adaptive Tooling for Complex Composite Blade Structures. TECHNICAL DESCRIPTION: Main rotor blades that incorporate features to reduce the static and dynamic radar signatures are difficult to manufacture because of inherently different physical characteristics of the materials used for signature suppression. Precision position control of individual internal blade components often dictates multiple cure cycles and bond and assembly jigs to maintain proper alignment and tolerances. We desire research to develop methods of curing and bonding components of complex blades so that the resultant product is dimensionally accurate, structurally sound, and fully cured, with minimal residual internal stresses. Low observability features are not required to bid on this program, but the baseline blade should be sufficiently complex to benefit from a redesign effort to integrate several subassemblies for cost effectiveness or structural efficiency. The successful offeror should demonstrate the ability to provide required cure and consolidation energy input to sections of varying thickness. Methods to include metal lugs and fittings into net consolidated parts are also desired. A representative blade section should be fabricated to demonstrate that dimensional tolerances can be maintained with no warping, twisting, or unacceptable residual stresses in the finished part. Limited static and fatigue testing, as appropriate, should be conducted to substantiate the structural integrity of the finished part. ANTICIPATED AMOUNT OF CONTRACT AWARD(S) (RANGE): $550k- $650k. ANTICIPATED PERFORMANCE PERIOD: Not to exceed 42 months (39 months for completion of technical and an additional 3 months for data submittal). TOPIC 04-97: Metal Matrix Landing Gear. TECHNICAL DESCRIPTION: In order to meet stringent criteria necessary to make helicopters more survivable in crashes, landing gear systems have become increasingly larger and heavier. Vehicle performance and signature requirements dictate that the gear be retractable without sacrificing their energy absorption capability. A current-technology, crashworthy, retractable system represents an unacceptably high fraction of the airframe weight. We desire development of advanced landing gear components that incorporate extremely high modulus, high fracture toughness metal matrix composite materials. The objective of this program is to design and fabricate a helicopter landing gear component incorporating aluminum matrix composites to demonstrate lightweight energy absorption compared to a component using aluminum or steel alloys. Demonstrate a reduced landing gear-to-airframe weight fraction compared to a selected baseline, while increasing the design fraction of energy absorbed for the landing gear portion of the crash energy absorption system. Demonstrate the energy absorption capability through limited component testing. ANTICIPATED AMOUNT OF CONTRACT AWARD(S) (RANGE): $450k - $550k. ANTICIPATED PERFORMANCE PERIOD: Not to exceed 32 months (29 months for completion of technical and an additional 3 months for data submittal). TOPIC 05-97: Cargo Rotorcraft Crashworthiness. TECHNICAL DESCRIPTION: The U.S. Army has taken a leading role in the development of crashworthiness technology. Significant advancements have occurred over the last 10 years in crash survival technology. These developments now make it possible to further refine crash resistance design criteria. This program will investigate the influence of design variables on the level of large rotorcraft crash resistance. This will be accomplished by conducting a survey of Government and industry crash data and survival technology and using this data to develop computer models for comparing system weight versus cost. Analysis will then be conducted on various crash survival components to optimize the cost/weight/performance of these components to achieve the highest levels of system performance. A crashworthy aircraft system would be proposed, upon completion of the analysis. For the purpose of this program, large rotorcraft are defined as those over 12,000 Kg DGW. ANTICIPATED AMOUNT OF CONTRACT AWARD(S) (RANGE): $300k - $400k. ANTICIPATED PERFORMANCE PERIOD: Not to exceed 24 months (21 months for completion of technical and an additional 3 months for data submittal). DELIVERABLES: All contracts awarded under this solicitation will require delivery of the following data items: (1) Draft and Reproducible Final Reports in Contractor Format (DI-MISC-80711), (2) Monthly Cost and Performance Reports (DI-FNCL-80912), (3) Monthly Technical Letter Progress Reports, (4) Test Plans (if applicable), and (5) Developmental Drawings (if applicable). FINAL BRIEFING: All contracts awarded under this solicitation will include a requirement for the Contractor to present the results of their work in a final briefing at Ft. Eustis, Virginia upon completion of all technical work under the contract. EVALUATION CRITERIA: The selection of one or more sources for contract award will be based on a scientific and/or engineering evaluation of proposals (both technical and cost as it relates to technical effort) in accordance with the criteria set forth in this section. Proposals will be evaluated on their own merit without regard to other proposals submitted under this announcement. These evaluations will result in narrative ratings which will be used to develop an order of merit listing for proposals submitted under each topic. Proposed cost will be evaluated, as appropriate, for realism and reasonableness. The evaluation criteria are (1) The extent to which the proposed work satisfies an Army research need by use of innovative, creative, affordable and efficient approaches to the technical problem. (2) The merit of the offeror's proposed approach to accomplish the scientific and technical objectives. (3) The experience and qualifications of scientists, engineers, technicians and other proposed personnel. (4) The suitability and availability of proposed facilities. (5) Cost. (END PART 1 OF 2) See Numbered Note(s): 26. (0270)

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