Research, Development, and Demonstration of Metal Casting Research to Increase the Competitiveness of the U.S. Foundry Industry

DEPARTMENT OF ENERGY

Research, Development, and Demonstration of Metal Casting

Research to Increase the Competitiveness of the U.S. Foundry Industry

AGENCY: Department of Energy, Idaho Operations Office.

ACTION: Solicitation for Financial Assistance: Metal Casting

Competitiveness Research Program.

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SUMMARY: The U.S. Department of Energy (DOE) Idaho Operations Office

(ID), is seeking applications for cost-shared research and technology

development in the U.S. metal casting industry. The objective is to

promote the competitiveness and energy efficiency of the U.S. metal

casting industry through major gains in manufacturing productivity;

remediation technologies; process cost reduction; and product quality

improvement. This is a complete solicitation document. No other

solicitation will be issued for this Metal Casting Competitiveness

Research Program.

DATES: The deadline for receipt of applications is January 19, 1995.

ADDRESSES: Applications shall be submitted to: B. G. Bauer, Contracting

Officer; Procurement Services Division; U. S. Department of Energy;

Idaho Operations Office; 850 Energy Drive, MS 1221; Idaho Falls, Idaho

83401-1563. [NUMBER DE-PS07-95ID13339]

FOR FURTHER INFORMATION CONTACT: Carol Bruns, Contract Specialist,

(208) 526-1534.

SUPPLEMENTARY INFORMATION:

Background

In order to improve the competitiveness and energy efficiency of

the U.S. metal casting industry, the Office of Industrial Processes

(OIP) of the DOE has sponsored a R&D program titled Metal Casting

Competitiveness Research Program. As part of this program, this

solicitation for federal financial assistance applications is being

issued.

Project Description

DOE anticipates awarding approximately two to eight Cooperative

Agreements in accordance with DOE Financial Assistance regulations

appearing at Title 10 of the Code of Federal Regulations, Chapter II

Subchapter H, Part 600 as a result of this solicitation, provided

applications received meet or further the objectives of Public Law 101-

425, Department of Energy Metal Casting Competitiveness Research Act of

1990, and funds are available. Federal funds appropriated for this

solicitation are approximately $1,750,000 and are to be used to fund

the entire research effort. The Catalog of Federal Domestic Assistance

Number for this program is 81.078. Each award will make available

federal funds to a project on a cost-sharing basis, but the federal

funding contribution will not exceed 50 percent of the total cost of a

research project. Under Cooperative Agreements it is anticipated there

will be substantial involvement by DOE.

DOE suggests, but does not require, a multi-phase approach and

projects may be initiated at the bench (Phase I), laboratory (Phase

II), or pilot-scale (Phase III), levels. The period of performance for

Phase I is anticipated to be 12 months. At the end of Phase I, provided

satisfactory progress has been made and funds are available, DOE may

award a continuation of work to undertake further development if the

participant demonstrates a continuing need for federal assistance,

shows sufficient progress in the research effort in Phase I, has

completed Phase I in compliance with a mutually agreed management plan,

and identifies the new research planned.

The thrust of the Program is directed towards R&D which will

improve the competitive position and energy efficiency of the U.S.

metal casting industry, defined as the industries identified by codes

numbered 3321, 3322, 3324, 3325, 3363, 3364, 3365, 3366, and 3369, in

the Standard Industrial Classification manual published by the Office

of Management and Budget in 1987. Utilizing the recommendations of the

DOE Metal Casting Industrial Advisory Board, and in accordance with the

objectives of Public Law 101-425, the below listed priority research

subject areas have been identified. Proposals for research in areas not

included in the list below will not be considered. Applications must

identify the priority area being addressed, explain why industry is not

already performing the proposed research, and why DOE funding is

appropriate.

Metal Casting Research Priorities

This solicitation is to be focused on the following metal casting

research priorities identified by the industry and the Industrial

Advisory Board.

1. Solidification and Casting Technologies:

a. Dimensional control of castings,

b. Clean cast metal technology,

c. Lost Foam casting technology,

d. Cast metal properties,

e. Porosity and inclusion defect elimination technology,

f. Thixotropic molding and rheocasting,

g. Solidification technology.

2. Computational Modeling and Design:

a. Computer integrated processing methods for productivity and

quality improvements such as Computer Aided Design (CAD), Computer

Aided Engineering (CAE), Computer Aided Manufacturing, (CAM), and

Computer Integrated Manufacturing (CIM),

b. Interaction of process variables,

c. Predictive Cupola furnace model,

d. Thermophysical property data base development for commercial

casting alloys.

3. Processing Technologies and Design for Energy Efficiency, Material

Conservation, Environmental Protection, or Industrial Productivity:

a. Energy Efficiency:

(1) Aluminum furnace optimization,

(2) Cupola furnace optimization,

(3) Waste heat recuperation for melting and holding furnace and

process ovens.

b. Material Conservation:

(1) Process improvements for lightweight components of aluminum and

magnesium,

(2) Net shape casting such as permanent molding and high pressure

die casting with disposable core and investment casting technologies,

(3) Improved molten metal delivery system designs,

(4) Net shape high modulus ferrous casting technology (Steel),

(5) Thin wall metal casting technology (ferrous and non-ferrous).

c. Environmental Protection:

(1) Sand reclamation,

(2) Characterization of waste streams,

(3) Waste treatment technologies and utilization.

d. Industrial Productivity:

(1) Gating system removal and finishing operation technologies,

(2) Core removal technology,

(3) Core assembly automation,

(4) Lead time compression technology.

4. Other Areas of Research:

a. On-line process controls (sensors) for molding, melting, and

coremaking,

b. Plasma melting,

c. Cokeless Cupola,

d. Metal matrix composite materials,

e. Extended die casting die life,

f. Development of advanced alloy technologies.

Proposal Requirements

Each proposal must contain the following:

1. Identify the priority area being addressed, explain why industry is

not already performing the proposed research, and why DOE funding is

appropriate;

2. Demonstrated support of the metal casting industry by describing:

a. how industry has participated in deciding what research

activities will be undertaken;

b. how industry will participate in the evaluation of the

applicant's progress in research and development activities;

c. the extent of industry involvement in conducting trials at

multiple plants to accomplish or validate the research; and

d. the extent to which industry funds are committed to the

applicant's proposal;

3. Demonstrate a commitment for matching funds from non-federal

sources, which shall consist of:

a. cash, and/or

b. as determined by DOE, the fair market value of equipment,

services, materials, appropriate technology transfer activities, and

other assets directly related to the proposed project;

4. Provide a single or multiyear management plan that outlines how the

research, development, and technology transfer activities will be

carried out and administered. The management plan shall:

a. outline the research, development, and technology transfer

activities by Task expected to be performed;

b. outline who will conduct those research activities;

c. establish the time frame over which the research activities will

take place; and

d. define the overall program management and direction by:

1. identifying managerial, organizational and administrative

procedures and responsibilities;

2. outlining how the coordination of research and development

between the individuals and organizations involved will be achieved;

3. demonstrating how implementation and monitoring of the progress

of the research project after receipt of funding from DOE will be

achieved;

4. demonstrating how recommendations and implementations on

modifications to the plan, if any, will be achieved; and

5. providing sufficient rationale to support the project costs.

5. State the annual cost of the proposal and a breakdown of those costs

per each task and each individual performing the work;

6. Provide a critical review of existing and emerging technologies,

relevant patents, on-going research, and practices, and a description

of the hurdles that must be overcome to ensure commercial viability and

commercialization of the proposed technologies;

7. Justify the project with an initial economic evaluation indicating

the potential for a significant reduction in manufacturing cost and/or

a significant improvement in product value resulting from the proposed

research;

8. Identify the technical hurdles for commercialization and how they

will be addressed; and

9. Provide evidence of having the facilities and equipment capable of

conducting at least laboratory scale testing or demonstration of metal

casting or related processes.

Note: Underlying assumptions along with detailed calculations to

support the claimed economic and energy efficiency benefits must be

included in the application.

Qualified Applicants

The following entities that are located in a region where the metal

casting industry is concentrated are qualified to respond to this

solicitation:

a. an educational institution;

b. a consortium of educational institutions;

c. a consortium of educational institution(s) with one or more of the

following: Government-owned laboratories, private research

organizations, nonprofit institutions, or private firms.

Proposal Evaluation

a. Application Deadline: The deadline for receipt of applications

is January 19, 1995. Late applications will be handled in accordance

with 10 CFR 600.13.

b. Selection of Proposals: Only those proposals which meet all of

the requirements of this solicitation will be considered for selection.

Selections will be made in accordance with the following selection

criteria and programmatic considerations:

Criterion 1--The research proposal demonstrates a thorough

knowledge of the metal casting industry by highlighting its technology

needs, barriers to their development and commercialization, and

provides a credible management plan to achieve, and evidence to

support, the benefits identified in the proposed research.

Criterion 2--The research proposal contains evidence of strong

support by the metal casting industry by identifying significant

industry involvement in preparation of the proposal and in performing

the research activities.

Criterion 3--The research proposal identifies a viable mechanism to

facilitate the transfer of the technology to the metal casting industry

at the earliest practicable time; Proposals that include conducting

trials at multiple plants to accomplish or validate work are preferred.

Criterion 4--The research proposal offers technology which is based

upon sound scientific, environmental, and engineering principles, are

technically feasible and cost effective, have practical industrial

application, and will provide the greatest benefits per dollar invested

in U.S. metal casting industry competitiveness and job creation and/or

retention.

Criterion 5--The extent of the financial commitment of non-Federal

sources to the research activities above and beyond the minimum 50%

requirement.

c. Weighting of Criteria: Criterion 1 is weighted 50%, Criteria 2

is weighted 20%, and Criteria 3, 4, and 5 are weighted 10% of the total

score.

d. Programmatic Selection Considerations: In conjunction with the

evaluation results and rankings of individual proposals, the Government

will make selections for negotiations and planned awards from among the

highest ranking proposals utilizing the following programmatic

considerations:

(1) To the greatest extent possible and subject to available

appropriations, selection decisions will ensure that at least one

applicant is selected from each of the four census regions of the

country where the metal casting area is concentrated (see Section 3 of

Public Law 101-425). A list of the four census regions will be included

in the application package.

(2) It is desirable to implement each research and development

project as a continuing collaborative effort in which the participants

represent both the scientific/engineering research disciplines as well

as members of the metal casting industry engaged in its practical,

daily operations and experienced in the application of advanced metal

casting processes.

(3) To the maximum extent possible, the research and development

activities should be conducted on the premises of the industrial

participants in the proposed projects.

(4) It is desirable that a dominant portion of the proposed

research focus on improving metal casting processes and the application

of emerging advanced technologies in the typical U.S. metal casting

company.

(5) Proposals that have the potential to save significant energy

and provide significant cost benefits are preferred.

(6) Proposal teams which include historically black colleges and

universities are preferred.

e. Merit Reviews: All Applications will be evaluated under the

Office of Energy Efficiency and Renewable Energy Merit Review of

Discretionary Financial Assistance Applications Review Procedures for

Solicited Proposals. The procedure for ``Objective Merit Review of

Discretionary Financial Assistance Applications'' was published in the

Federal Register on May 31, 1990 (Vol. 55, No. 105). Selections for

negotiations are expected to be made February 28, 1995, and financial

assistance awards are expected to be made by June 30, 1995.

General Conditions

The applications will be evaluated in accordance with the Office of

Energy Efficiency and Renewable Energy Merit Review Procedure, and the

criteria and programmatic considerations set forth in this

solicitation. In conducting this evaluation, the Government may utilize

assistance and advice from non-Government personnel. Applicants are

therefore requested to state on the cover sheet of the applications if

they do not consent to an evaluation by such non-Government personnel.

The applicants are further advised that DOE may be unable to give full

consideration to an application submitted without such consent. DOE

reserves the right to support or not to support any, all, or any part

of any application. All applicants will be notified in writing of the

action taken on their applications in approximately 90 days after the

closing date for this solicitation, provided no follow-up

clarifications are needed. Status of any application during the

evaluation and selection process will not be discussed with the

applicants. Unsuccessful applications will not be returned.

Instructions for Preparation of Applications

Each application in response to this solicitation should be

prepared in one volume. One original and nine copies of each

application are required. The application facesheet is the Standard

Form 424. The application is to be prepared for the complete project

period.

a. Proprietary Proposal Information: Applications submitted in

response to this solicitation may contain trade secrets and/or

privileged or confidential commercial or financial information which

the applicant does not want used or disclosed for any purpose other

than evaluation of the application. The use and disclosure of such data

may be restricted provided the applicant marks the cover sheet of the

application with the following legend, specifying the pages of the

application which are to be restricted in accordance with the

conditions of the legend:

The data contained in pages ______ of this application have been

submitted in confidence and contain trade secrets or proprietary

information, and such data shall be used or disclosed only for

evaluation purposes, provided that if this applicant receives an

award as a result of or in connection with the submission of this

application, DOE shall have the right to use or disclose the data

herein to the extent provided in the award. This restriction does

not limit the government's right to use or disclose data obtained

without restriction from any source, including the applicant.

Further, to protect such data, each page containing such data shall

be specifically identified and marked, including each line or paragraph

containing the data to be protected with a legend similar to the

following:

Use or disclosure of the data set forth above is subject to the

restriction on the cover page of this application.

It should be noted, however, that data bearing the aforementioned

legend may be subject to release under the provisions of the Freedom of

Information Act (FOIA), if DOE or a court determines that the material

so marked is not exempt under the FOIA. The Government assumes no

liability for disclosure or use of unmarked data and may use or

disclose such data for any purpose. Applicants are hereby notified that

DOE intends to make all applications submitted available to non-

Government personnel for the sole purpose of assisting the DOE in its

evaluation of the applications. These individuals will be required to

protect the confidentiality of any specifically identified information

obtained as a result of their participation in the evaluation.

b. Budget: A budget period is an interval of time (usually 12

months) into which the project period is divided for funding and

reporting purposes. Project period means the total approved period of

time that DOE will provide support contingent upon satisfactory

progress and availability of funds. The project period may be divided

into several budget periods. The project period shall not exceed three

years. Each application must contain Standard Forms 424 and 424A. The

budget summary page only needs to be completed for the first budget

period; all other periods of support requested should be shown on the

total costs page. The proposal should contain full details of the costs

regarding the labor, overhead, material, travel, subcontracts,

consultants, and other support costs broken down per task and per year.

Every cost item should be justifiable and further details of the costs

may be required if the proposal is selected for the award. It is

essential that requested details be submitted in a timely manner for

the actual award. Items of needed equipment should be individually

listed by description and estimated cost, inclusive of tax, and

adequately justified. The destination and purpose of budgeted travel

and its relation to the research, should be specified. Anticipated

consultant services should be justified and information furnished on

each individual's expertise, primary organizational affiliation, daily

compensation rate and number of days of expected service. Consultant's

travel costs should be listed separately under travel in the budget.

c. Cost: In the event there are multiple projects proposed in a

submittal, a separate cost proposal should be included for each project

proposed for funding. The cost proposal should have sufficient detail

that an independent evaluation of the labor, materials, equipment and

other costs as well as a verification of the proposed cost share can be

performed.

Notices to Applicants

a. False Statements: Applications must set forth full, accurate,

and complete information as required by this solicitation. The penalty

for making false statements is prescribed in 18 U.S.C. 1001.

b. Application Clarification: DOE reserves the right to require

applications to be clarified or supplemented to the extent considered

necessary either through additional written submissions or oral

presentations.

c. Amendments: All amendments to this solicitation will be mailed

to recipients who submit a written request for the application forms.

d. Applicant's Past Performance: DOE reserves the right to solicit

from available sources relevant information concerning an applicant's

past performance and may consider such information in its evaluation.

e. Commitment of Public Funds: The Contracting Officer is the only

individual who can legally commit the Government to the expenditure of

public funds in connection with the proposed award. Any other

commitment, either explicit or implied, is invalid.

f. Effective Period of Application: All applications should remain

in effect for at least 180 days from the closing date.

g. Availability of Funds: The actual amount of funds to be

obligated in each fiscal year will be subject to availability of funds

appropriated by Congress to carry out the purposes of the Act (Public

Law 101-425).

h. Assurances and Certifications: DOE requires the submission of

preaward assurances of compliance and certifications which are mandated

by law. The assurance and certification forms will be provided in the

application package which will be provided to you upon written request.

i. Preaward Costs: The government is not liable for any costs

incurred in preparation of an application. Awardees may incur preaward

costs up to ninety (90) days prior to the effective date of award.

Should the awardee take such action, it is done so at the awardee's

risk and does not impose any obligation on the DOE to issue an award

(10 CFR 600.103)

j. Patent Rights: Pursuant to the direction in Section 9 of Public

Law 101-425, applicants are advised that patent rights will be treated

in accordance with Chapter 18, Title 35 of the United States Code.

k. Loans under DOE Minority Economic Impact (MEI) Loan Program:

Applicants are advised that loans under the DOE Minority Economic

Impact (MEI) Loan Program are not available to finance the cost of

preparing an application pursuant to this solicitation.

l. Environmental impact: The applicant shall include a listing,

discussion and existing documentation if the project/activity has the

possibility of involving, generating or resulting in changes to any of

the following: (1) Air Pollutants--released or discharged into the

atmosphere through point or fugitive sources; (2) Liquid Effluent--any

waste stream discharged; (3) Solid Waste--nonradioactive, nonhazardous

solid waste; (4) Radioactive Waste--waste containing >2 nCi/g; (5)

Hazardous Waste--RCRA hazardous per 40 CFR 261.3 and polychlorinated

biphenyls (PCBs); (6) Mixed Waste--combination of radioactive and

hazardous waste; (7) Chemical Storage/Use--define species, uses and

estimates volumes; (8) Petroleum Products Storage--define product,

volume, use and type of storage; (9) Asbestos Waste--define friability,

estimated volume, and if project is renovation or demolition; (10)

Water Use/Diversion--withdrawal of groundwater or diversion or

withdrawal of surface water; (11) Sewage System--all pipes, tanks,

treatment structures; disposal areas, etc. for collection, treatment,

and disposal of sewage; (12) Clearing/Excavation--removal of surface

debris, vegetation, and other changes in soil surface features; (13)

Construction/Renovation; (14) Excess Noise Levels--ambient noise level

name, near proposed project/activity; (15) Pesticide Use--identify

pesticide name, target organism, use area, application rate, method,

and applicator; (16) Radiation Exposures--radiation levels at or near

the proposed project/activity.

The discussion shall address the following questions. Will this

action contribute to a cumulative impact with on-going activities? Is

this action related to a proposed action with potentially significant

impacts? Will the project create uncertain, unique, or unknown risks?

Will the project require siting, construction, or expansion of a waste

facility? Will the project impact a RCRA-regulated unit or facility?

Will the project threaten or violate any statute, regulation, or DOE

Order? Will the project require any federal, state, or local permits,

approvals, etc.? Has this action/area been previously assessed under

NEPA? Will the action take place in an area of previous or on-going

disturbance? Will the action have any socioeconomic concerns?

Will the project adversely affect any of the following

environmentally sensitive resources? (1) Threatened/Endangered Species;

(2) Wildlife/Vegetation; (3) Soils/Erosion; (4) Cultural/Historical;

(5) Wilderness/Scenic Areas; (6) Prime/Unique Farmland; (7) Wild/Scenic

Rivers; (8) Lakes/Floodplains/Wetlands; (9) Domestic/Groundwater; (10)

Air Resources/Quality. Discussions shall include how all environmental

impacts will be mitigated. If an environmental impact cannot be

mitigated, what are the direct and indirect, short term and long term

adverse effects that can not be avoided?

m. Applicants shall be required to comply with Section 2306 of the

Energy Policy Act of 1992 (EPACT) [42 U.S.C. 13525], in the event EPACT

applies to financial assistance instruments issued as a result of this

solicitation. A copy of Section 2306 will be included in the

application package.

In order to receive a copy of the application package, please

submit a written request or fax to the following address. U.S.

Department of Energy, Idaho Operations Office, 850 Energy Drive, Idaho

Falls, ID 83401-1563, Attn: Carol Bruns MS-1221, Fax No. (208) 526-

5548.

The Procurement Request No. is 07-95ID13339.000. To facilitate

handling, please place the Procurement Request No. on the facsimile or

outside of the package containing your request for the application

forms.

Issued in Idaho Falls, Idaho on November 9, 1994.

R.J. Hoyles,

Director, Procurement Services Division.

[FR Doc. 94-29364 Filed 11-28-94; 8:45 am]

BILLING CODE 6450-01-P