[Federal Register Volume 59, Number 44 (Monday, March 7, 1994)]
[Unknown Section]
[Page 0]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 94-5139]


[[Page Unknown]]

[Federal Register: March 7, 1994]


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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