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

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URL: https://www.frixlaw.com/law-library/documents/fr%3A94-29364

## Record

- **Collection:** Federal Register
- **Document type:** Uncategorized Document
- **Published:** November 29, 1994

## Text

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

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