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: Notice is hereby given that pursuant to Public Law 101-425,

Department of Energy Metal Casting Competitiveness Research Act of

1990, 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 April 29, 1994.

ADDRESSES: Applications shall be submitted to: [Number DE-PS07-

94ID13293] J.O. Lee, Contracting Officer; Contracts Officer;

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

Operations Office; 785 DOE Place, MS 1221, Idaho Falls, Idaho 83401-

1562.

FOR FURTHER INFORMATION CONTACT: Trudy Thorne, Contract Specialist,

(208) 526-9519.

SUPPLEMENTARY INFORMATION:

Background

The U.S. metal casting industry has been losing its competitive

position in the domestic marketplace relative to imported castings for

a number of years. The domestic metal casting industry, with costs

which are typically 40 to 50 percent for charge materials, 20 to 30

percent for labor, and 15 to 20 percent for energy, is generally at a

disadvantage when compared to most foreign competitors. In addition,

many foreign competitors obtain R&D assistance funded by their

governments. Moreover, they are not required to meet stringent

environmental regulations, while the ability of the U.S. metal casting

industry to compete is adversely affected because of the expense of

complying with rules and regulations intended to protect the

environment and the work place. These advantages often outweigh the

additional transportation and distribution costs incurred by foreign

competitors entering the U.S. market for metal castings. A technically

advanced and viable metal casting industry is essential to the

competitiveness of many American industries. Many metal casting

companies lack the resources to conduct metal casting research alone

due to the fragmented nature of the industry.

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 (MCCRP). 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 as a result of this solicitation provided applications

received meet or further the objectives of Public Law 101-425 and funds

are available. Federal funds appropriated for this solicitation are

approximately $1,900K. 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. Applicants should focus their

effort on the seven subject areas identified with an asterisk (*),

which have the highest priority. One, or more, of the lower priority

listed subjects may be included in the proposed research. Proposals for

research in areas not included in the list below will not be

considered. Applications should 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. Expendable pattern casting technology.

2. 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).

3. Processing Technologies and Design for Energy Efficiency, Material

Conservation, Environmental Protection, or Industrial Productivity:

a. Energy Efficiency:

* (1) Melting Furnace Optimization.

b. Material Conservation:

* (1) Casting process improvements for lightweight and thin-wall

components of aluminum, and magnesium etc.

c. Environmental Protection:

* (1) Sand reclamation.

* (2) Characterization and remediation of waste streams.

d. Industrial Productivity:

(1) Gating system removal technologies.

4. Other Areas of Research:

a. On-line process control and sensors for molding, melting, and

coremaking.

b. Improved melting process for casting purposes.

Proposal Requirements

Each proposal must contain the following:

1. 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; and

c. The extent to which industry funds are committed to the

applicant's proposal.

2. 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 proposal's cost;

3. 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 that

shall:

a. Outline the research, development, and technology transfer

activities expected to be performed;

b. Outline who will conduct those research activities;

c. Establish the duration of each task and 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 research project after receipt of funding from the

Secretary 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.

4. State the annual cost of the proposal and a breakdown of

those costs per each task and each individual performing the work;

5. 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;

6. 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;

7. Identify the technical hurdles for commercialization and how

they will be addressed; and

8. 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 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;

That is located in a region where the metal casting industry is

concentrated.

Proposal Evaluation

a. Application Deadline: The deadline for receipt of

applications is April 29, 1994. Only applications which are timely

in accordance with 10 CFR 600.13, will be evaluated. 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 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 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;

Criterion 4--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; and

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

Federal sources to the research activities.

c. Weighting of Criteria: Selection criterion (given under F.b.

above) Criterion 1 is weighted 60% of the total score. Criteria 2,

3, 4, and 5 are weighted equal, each one being 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.

(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.

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

Office of Conservation and Renewable Energy Merit Review of

Discretionary Financial Assistance Applications Review Procedures

for Solicited Proposals. Selections for negotiations are expected to

be made May 31, 1994, and financial assistance awards are expected

to be made by August 31, 1994.

Conditions, Instructions, and Notices

General Conditions

The applications will be evaluated in accordance with the

applicable DOE Financial Assistance Rules, Code of Federal Regulations

Title 10, Chapter II, Subchapter H, part 600, 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 six 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. Each application must contain

Standard Forms 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

(Pub. L. 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.

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?

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, 785 DOE Place,

Idaho Falls, ID 83401-1562, Attn: Trudy Thorne MS-1221, Fax No.

(208) 526-5548

The Procurement Request No. is 07-94ID13293.000. To facilitate

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

outside of the package containing your request for the application

forms:

Solicitation: DE-PS07-94ID13293.

Dated: February 25, 1994.

J.O. Lee,

Acting Director, Procurement Services Division.

[FR Doc. 94-5139 Filed 3-4-94; 8:45 am]

BILLING CODE 6450-01-P