Narrow-Gap Improved Electroslag Welding of High Performance Steel for Bridges

Broad Agency Announcement No. DTFH61-09-R-00003 Narrow-Gap Improved Electroslag Welding of High Performance Steel for Bridges A. Background ASTM A709, Grade 70W high performance steel is being increasingly used for bridges in the United States. The Narrow Gap Improved Electroslag Welding process (ESW-NG) developed under long term research sponsored by the Federal Highway Administration, developed in the 1980's and 1990's for welding conventional A36 and A588 structural steels is a greatly improved modification of conventional consumable guide electroslag welding. This research was conducted at the Oregon Graduate Institute (OGI), Beaverton, OR (FHWA technical report on ESW-NG; Number FHWA/RD-87/026, available from the Sales Department of the National Technical Information Service, telephone number 703-605-6000 or 800-553-6847, publication number PB89211056). ESW-NG results in major increases in productivity in an already high productivity welding process, virtually eliminates weld defects, increases process reliability, and improves both weld metal and heat affected zone impact toughness. Fatigue tests on I-Beams demonstrated excellent fatigue properties. The previous research and the demonstrations that followed the research were limited to conventional steels. Now, with the advent of high performance steels, there is an urgent need to determine whether or not Narrow Gap-Improved Electroslag (ESW-NG) welding process could be allowed for joining High Performance Steel (HPS) also. The previously developed ESW-NG process consumables and welding conditions may have to be modified for joining HPS to ensure that welded joints thus made will be defect free and will have adequate strength and toughness in both the weld metal and heat-affected zones of the welded joints. The assessment of the weldment properties that can be achieved through the integration of both these new technologies, steel production and high productivity joining, needs to be carried out to determine the potential for, and the benefits of, ESW-NG applied to HPS 70W. The lack of preheating requirements, the extremely high weld productivity, and the cost effectiveness in thicknesses over 25 mm are strong drivers for use of the technology. Effective use of shop floor space and reduced plate handling also enhance fabrication efficiency. The consumable development, while designed for conventional steels, will use the same wire chemistry principles as those applied to welding HPS Gr 70W - low carbon and the use of Ni-Mo-Mn to develop high weld metal toughness and matching strength, while minimizing carbon content. The consumable chemistry will likely need to be slightly modified in order to match the 70 ksi strength level, since the weld metal strength for ESW-NG of A588 using the current weld metal chemistry is typically 68,000psi. and since the weld metal carbon content for A588 is typically around 0.09wt % carbon (after dilution from the base metal) and the carbon content for ESW-NG Gr70 is expected to be as low as 0.05wt %C. Some adjustment in the Ni-Mn- Mo levels can be anticipated in order to achieve a yield strength of between 72,000 psi and 74,000 psi. The second area of concentration will be to reduce the heat input to as low a level as can be practically and consistently achieved in order to maximize the heat affected zone properties. C. Objectives The primary objectives of this basic/applied research are to apply and extend ESW-NG practices and consumable development for application to HPS 70W. The two technical areas of concentration will be (1) evaluating consumable chemistry requirements and the resulting weld metal chemistry to achieve (a) a minimum 70 ksi strength level and (b) a weld metal microstructure with the maximum level of impact toughness, and (2) process modifications that will reduce the heat input to a minimum level that can be consistently and practically achieved in a production environment. For both objectives the starting baseline point of comparison will be the current wire chemistry and the current baseline recommended welding process parameters. D. Requirements Technical Approach The Contractor's proposal shall delineate a technical approach taking into consideration of weld metal chemistry, grain structure and metallurgy and heat input which may influence mechnical properties of the weldment and heat affected zones (HAZ). Because there are a number of variables that can influence heat input which can influence HAZ microstructure and properties, the technical approach and the assessment will be to maximize the mechanical properties. The assessment of the weld quality and HAZ should include the following factors at a minimum: (1) Application of a thin metal sheath for the tubular metal powder cored electrode wire (2) Application of multiple 1/16" diameter electrode wire rather than the typical single 3/32" diameter wire: (3) Application of multiple electrodes (2 versus 1) in order to reduce the current density for each wire (4) Increasing the water cooling effectiveness of the retaining shoes by increasing the water flow rate and by reducing the incoming water temperature The Government anticipates an approach which would focus on optimizing tensile properties and impact toughness while maintaining - consistency, reliability, defect free, and demonstrated fatigue behavior. Standards for the evaluation of test welds and specimens shall be consistent with tests required by the current AASHTO/AWS D1.5 Bridge Welding Code procedures and as noted below: Transverse Tensile Tests All Weld Metal Tensile Tests Radiographic Tests (RT) and Ultrasonic Tests (UT) Bend tests Weld metal and Heat Affected Zone Hardness Tests Weld metal Charpey V Notch (CVN) (8) mid thickness Heat Affected zone CVN (5) quarter thickness weld and heat affected zone macro and microstructure analysis Additional analysis beyond standard D1.5 protocols will include weld metal chemistry. The Government anticipates that initial weld samples shall be evaluated primarily for weld integrity, weld cross section profile, and dilution, rather than for tensile strength and toughness and the full complement of D1.5 weld evaluation methods to fully evaluate the optimized HPS Gr 70W weldment including HPS Gr70W to conventional structural steel, such as A588, hybrid weldments. The thickness of the weldments will be dependent on the available test plate material. Suitable thicknesses range from about 38 mm (1.5") to 100 mm (4") thick. Since HPS Gr. 70W is not available in 100 mm (4) thickness, the Government anticipates that the Contractor shall make hybrid weldments using conventional steel up to 100mm (4) plate and the second plate up to 76 mm(3) HPS Gr70W. The exact thickness shall be proposed by the Contractor based on the plate availability and as approval by the Government. For estimating purposes two plate thicknesses are anticipated. It is anticipated that the Contractor shalll conduct optimization development of welds, including required weld analysis resulting in a weld procedure designed to minimize heat input levels to the lowest practical level. and electrode and consumable guide chemistry modification resulting in ESW-NG welds that meet minimum tensile properties for HPS Gr70W. The Contractor shalll conduct detailed impact toughness tests on fully optimized welds per proposed AASHTO/AWS D1.5 specifications for ESW-NG. Also, the Contractor shall evaluate mechanical properties of HPS optimized ESW-NG for hybrid welds (joining HPS to conventional steel). All test results, findings and recommendations shall be compiled in a report. The Government may post this report on the FHWA Web site. The contractor shall strictly follow FHWA Web posting protocols and 508 compliance. The Government anticipates a kick-off meeting and has capability of Web conferencing. Kick-off Web conference meeting shall be to seek directions from the COTR and the FHWA advisory group. The FHWA Web conferencing services will be used at no cost to the Contractor. The Contractor shall prepare a power point presentation and other necessary visuals to discuss the proposed work plan including a detailed (time) schedule for the test program. Based on the directions provided by the advisory group and upon approval by the Government, the Contractor shall update the work plan. After the kick-off meeting, the following shall be provided to the CO and to the COTR: (1) Hard copy of the work plan (2) Electronic copy of the work plan (3) The Contractor shall provide minutes of the meeting. The COTR may post these minutes on the FHWA Web site. The contractor will strictly follow FHWA Web posting protocols and 508 compliance. Test Matrix and Optimization of ESW-NG for HPS Gr70W The Government anticipates that the Contractor shall develop a test matrix consistent with the proposed research approach to produce sound optimized welds with tensile strength of that required for HPS Gr70W steel. The number of weldments and conditions considered in the test matrix will be rationalized by the contractor. Web meetings with the FHWA Advisory Group The Government anticipates that the Contractor shall utilize Web conference(s) (Web meetings). The FHWA Web conferencing services shall be used at no cost to the Contractor to present to the COTR and the FHWA advisory Group power point presentation(s) and other necessary visuals to discuss the research progress, test program results, research findings and recommendations including any modifications to the test program. Based on the directions provided by the advisory group and upon approval by the Government, after each web meeting, the Contractor shall update the test program and the work plan. Following the Web conference(s) meeting(s), the following shall be provided to the CO and the COTR, as applicable: (1) Hard copy of the revised test program including modified test matrix and the updated work plan. (2) Electronic copy of the updated work plan and updated power point slides (maximum 36 slides) suitable for posting on the FHWA Web site for dissemination of the related technical information among State DOTs, industries and other users. (3) The Contractor will provide minutes of the meeting. The COTR may post these minutes on the FHWA Web site. The contractor will strictly follow FHWA Web posting protocols and 508 compliance. After receipt, the final procedures for ESW-NG on HPS will be subject to peer or scientific review. E. Instructions for Preparation of Proposals The scope of this announcement is intentionally broad to invite innovation and to provide the FHWA the flexibility to sponsor research which best addresses its objectives. In keeping with FHWA's desire for innovation and flexibility, the specific approach in the selected proposal will be negotiated. FHWA anticipates awarding one contract. Any resulting contract will contain appropriate federal agency clauses for the type of procurement vehicle awarded, including any requirements for compliance with Section 508 of the Rehabilitation Act, as applicable. Prior to award, the Offeror shall be required to submit - Certifications and Representations, or have them published on the Online Representations and Certifications Applications website (www.orca.bpn.gov). Data and reporting requirements will be negotiated with the firm(s) selected for award(s). Offerors shall submit the following: Part I. Technical Proposal Within the total page limitation of fifteen (15) double spaced pages (See Section E - Proposal Format for more information) for this part, the Offeror's proposal shall include, but not be limited to, the following components and shall be organized accordingly: Problem Statement This will include a statement of the problem to be addressed and why it is an issue for bridge builders. The problem statement will address the national significance of the problem. This section will include proposed problem-related scenarios, and proposed problem-related evaluation measures. The page limitation for this section is not to exceed three (3) pages. Work Plan The work plan shall clearly indicate methodology for developing ESW-NG consumables for joining HPS. The work plan shall describe the necessary tasks required to develop, model, and evaluate the baseline and problem-related scenarios. The work plan shall describe a timeline for completion of each task and the interrelationships of all tasks. The task descriptions shall describe validation protocols, and methods for evaluating and presenting test results. FHWA Advisory Group Review All work plans must include preparation of read-ahead documents, presentation materials, meeting facilities, and a one day Web conference presentation to FHWA Advisory Group of the test results. In addition, at least one Web conference will be subsequently held to respond to reviewer comments. Members of the peer review will be identified in cooperation with FHWA. The FHWA Web conferencing services shall be used at no cost to the Contractor Data Sources Proposals shall clearly identify all data sources that will be used to accomplish the proposed work. This section shall also describe plans to develop code like specifications which will be presented and reviewed at the AWS D1.5 Bridge Welding Code Committee meeting (location of the meeting will be advised by the COTR). The page limitation for this section is not to exceed two (4) pages. Part II. Staffing Staffing Within the total page limitation of thirteen (13) pages for this part, the Offeror's proposal shall include, but not be limited to, the following components and shall be organized accordingly: - The names of all personnel and the position they will occupy as related to this project must be provided. - The estimated professional and technical staffing shall be provided in staff hours, on a task-by-task basis. - Tailored biographical summaries of key personnel shall also be included and shall not exceed three (3) pages per person. - Applicants must demonstrate experience in: (1) Electroslag welding (2) Consumable development (3) Developing specifications for adoption in Bridge Welding Code D1.5 - Teams should have computing expertise consistent with the project scope and technical proposal. Part III. Past Performance Offerors must submit information on all contracts/subcontracts involving similar or related services over the past three years with FHWA and/or other organizations (commercial, state and local, Federal, etc.). The offeror shall submit a minimum of three to four contract/subcontract descriptions for the entire proposed team (prime offeror plus major subcontractors). The offeror must submit this information on the most recently completed (within the past five years) contracts/subcontracts or ongoing contracts/subcontracts that are at least six months into the period of performance. The following information must be provided: - Customer name and address - Technical office point(s) of contact (name and telephone number) - Contracting/business office point(s) of contact (name and telephone number) - Contract number, if applicable - Date of contract award and period of performance - Type of contract - Total contract value at time of award - Brief description of product or services The offeror may identify any relevant quality awards or certifications that they have received over the past three years. In those instances where a new corporate entity lacks relevant past performance history, they may submit data on the individual components that comprise the new entity or on individual key personnel, with past performance history. FHWA may use this information to contact technical and business representatives on previous contracts to obtain information regarding performance. Failure to provide complete information regarding previous similar and/or related contracts may result in eventual disqualification. Offerors must identify any contract that was terminated for convenience of the Government within the past three years, and any contract that was terminated for default within the past five years. Briefly explain the circumstances in each instance. Part IV. COST The Offeror's cost proposal shall include, but not be limited to, the following components and shall be organized accordingly: Funding The cost or price proposal shall be specific, complete in every detail, and separate from the technical and staffing proposals. The cost or price breakdown shall be submitted utilizing Standard Form 1411 (Contract Pricing Proposal Sheet - Attachment No. 1) as a cover sheet, together with supporting detailed cost data, including any subcontractor data, in accordance with FAR 15.804-6. Spending Plan The estimated budget and spending plan for completion of the project must be identified. The maximum federal funding per award is $150,000. Cost Sharing (As applicable) Identify any cost sharing to be applied. For in-kind cost sharing provide the fair market value. While cost sharing is not required, an offeror may wish to include this to improve the value of their proposal. (FAR 35.003(b)) F. Proposal Format Each Offeror must submit an original copy of the proposal, with Part IV submitted as a distinct volume from Parts I, II, and III. Each Offeror must also submit a set in electronic format via email to Samantha.Reizes@dot.gov. Part I Technical Proposal: The technical proposal shall be limited to fifteen (15) pages. Part II Staffing Proposal: The staffing proposal shall be limited to thirteen (13) pages. The principal investigator qualifications shall be submitted as a separate resume within the page limit. Part III Past Performance: There is no page limit for past performance. Part IV Cost Proposal: There is no page limit for cost proposals. Parts I, II, and III shall be placed in the same binder. Part IV shall be in a separate binder. Proposals shall be submitted on 8.5 by 11 inch paper, except for foldouts used for charts, tables, appendices or diagrams, which shall not exceed 11 by 17 inches. A page is defined as one side of a piece of paper. A piece of paper with printing on both sides is considered 2 pages. Margins (excluding headers and footers) shall be no less than 1 inch on the sides, top and bottom of the page. Regular text print type shall not be less than 10 points or more than 12 character per inch, and shall not exceed 6 lines to the vertical inch. Pages exceeding the page limitation will not be read or evaluated. The evaluation board may take into account when making its evaluation, any failure to conform to the instructions and rules in this section or any attempt to evade these specifications and rules on the basis of technicalities, as indicators of future performance. If an Offeror does not understand these instructions, then they must submit their questions(s) to the Contracting Officer for clarification sufficiently in advance of the deadline for the receipt of offers to get an answer in time to meet that deadline. G. Submission of Proposals Proposals are due by 12:00 PM on Friday, December 5, 2008. Address your proposal to: Federal Highway Administration Office of Acquisition Management (HAAM-40) 1200 New Jersey Avenue, SE Room E65-101 Washington, DC 20590 Attention: Ms. Samantha Reizes NOTE: Security procedures prohibit non-uniformed couriers from delivering material directly to offices in the DOT building. Only uniformed couriers from FedEx and the United Parcel Service, who are dressed in a uniform bearing their organization's name and possessing official identification, may deliver proposals or sealed bids directly to the Office of Acquisition Management. Bids/offers must be received by the Office of Acquisition Management by the time and date due, to be considered timely, not just delivered to the mail room/visitor's center. To assist in expediting delivery, the outside of the envelope/package containing the offer must be marked with the completed Optional Form 17, Offer Label, available on line at http://www.fhwa.dot.gov/aaa/forms.htm. Further, please be advised that all of our mail (items handled by the U.S. Postal Service) is sent out of town for scanning and irradiation prior to delivery to the building. This process can add several days to your mailing time, even from local addresses. H. Deliverables The specific deliverables will depend upon the scope and objectives of the negotiated award. At a minimum, the contractor shall deliver the following: (1) Through the COTR (or as directed by the COTR), the Contractor shall prepare and present in the AASHTO/AWS D1.5 Bridge Welding Code Committee 20 copies of the draft - Specifications and Commentary for joining HPS using the ESW-NG process. Also, the COTR shall be provided an electronic version of the document submitted to the AASHTO/AWS D1.5 Committee, an electronic version of the corrected copy of the ESW-NG specifications and commentary after incorporating AASHTO/AWS D1.5 Committee recommendations, and (2) The final report of the research effort, including recommendations and findings for possible additional future work. I. Contract Period The contract period is negotiable but is anticipated to be nine months from date of award. J. Evaluation Criteria The primary basis for selecting proposals for acceptance shall be technical importance to FHWA programs, and fund availability. Cost realism and reasonableness shall also be considered. The following criteria, of approximately equal importance, shall be used in evaluating the technical merit of the proposals: 1. Demonstrated understanding of the problem 2. Research Approach to the problem statement 3. Qualifications, Abilities and Experience of proposed staffing 4. Capability of Offeror's facility for making and testing ESW welds K. Government Rights The Government anticipates that $150,000 will be dedicated to this BAA in FY 2009, and reserves the right to make single or multiple awards. Should additional funds for this program become available, the Government reserves the right to fund additional meritorious programs within thee stated proposal validity date. The Government reserves the right to incorporate ideas from successful offers into future contracts. The Government will not reimburse offerors for proposal or response preparation costs associated with this BAA.