A02.14 DOR_Galveston Sector Gear Top Hinge Replacement - 25 Apr 25.pdf

Description of Requirement

Wire Arc Additive Manufactured (WAAM) Parts

BACKGROUND:

The U.S. Army Engineer Research and Development Center (ERDC), Geotechnical and Structures Laboratory (GSL), Concrete and Materials Branch (CMB) requires the following specified additively manufactured part to replace the Sector Gear Top Hinge for the Brazos River west gate.

SPECIFICATIONS:

Sector gear top hinge replacement to be fabricated using wire arc additive manufacturing.

Sector Gear Top Hinge Physical Description:

• Sector gear top hinge length = 45” ( approx.)

• Sector gear top hinge Weight = 1527 lbs ( approx.)

• Sector gear top hinge Material: 3D Printed Steel – ER70s

• Sector gear top hinge Material Ultimate Strength: Su = 60 ksi ( minimum )

• Sector gear top hinge Material Yield Strength: Su = 45 ksi

• Sector gear top hinge Material Percent Elongation: = 20%

• Sector gear top hinge Material Vickers Hardness: HV10 = 280 ( maximum )

• The part must meet the minimum requirements for quality of ASTM A27 grade 2 for steel castings and 100% visual inspection of weld code D.1.5 (i.e. cracking, overlap, cold-roll, pin-holes, porosity, slag inclusion, etc.).

• The part must be manufactured out of a steel material meeting the above specifications.

• Part must be manufactured using the wire arc additive manufacturing (WAAM) process

• The constructed sector gear top hinge must be fabricated per the required material specification and have dimensional tolerances of +/-1/8” out of tolerance for all major dimensions such as hole centers, hole center to center distances, overall lengths and widths when compared to the Government provided 3D CAD file (3DHinge.stp). The WAAM made part must provide sufficient machining stock to allow for the machining of the machine finished surfaces shown on the machined part drawing.

• Sector gear top hinge must be fabricated and delivered in one piece by the Contractor. If there is a requirement to make the part in 2 pieces, then the Contractor will join the pieces together.

• If a splice (2 initial pieces joined together to have one final component) is required, a projected strength of the spliced area must be provided by the Contractor. ERDC and Galveston will review prior to award.

• Nondestructive testing and acceptance criteria shall be based on AWS D.1.5 (2020). Testing shall be performed on 100% CJP splice welds performed manually or with robotics. All splice welds shall be considered tension welds and subject to reversal of stress.

• Additive manufacturing procedure qualification must be in accordance with ASME BPVC SEC IX and in particular Article VI 'Material Manufacturing Using Wire-Additive Welding.' Additive Manufacturing work must be in accordance with AWS D20.1/D20.1M Specification for

Fabrication of Metal Components using Additive Manufacturing. In the event of conflicts between the two as it relates to qualification, the ASME BPVC governs. All components produced by additive manufacturing must be classified as Class A as defined in and utilized by AWS D20.1/D20.1M. All steel parts produced by additive manufacturing must be laser dimension verified, checked with a digital surface roughness tool, and subjected to 100% radiographic testing (RT).

• Shop performing additive manufacturing of steel parts must be qualified and experienced in performing additive manufacturing of steel parts using procedures qualified in accordance with Article VI of ASME BPVC SEC IX. Additive Manufacturing shop must have manufactured no less than three such steel parts with a primary dimension 1.5 feet or greater using such procedures in the last two years from contract award. Submit Qualifications for Additive Manufacturing Shop.

• Stress relieve parts following additive manufacturing and splicing and prior to machining and boring. All pinholes, surfaces to be in contact with others, and other surfaces called out as finished in the plans must be machined to the finish required. Surfaces not required in the plans to be machined to a particular finish must be hand ground to remove the irregular weld layers on the surface with weld spatter removed.

• Contractor must submit an Additive Manufacturing Build Plan for each part detailing how the part will be fabricated using additive manufacturing. Plan must include orientation of the part on the print surface, settings used in the generation of the g-code or equivalent code instructions for the printing equipment including tool pathing, weld procedures for the additive manufacturing process including weld power/current, wire diameter, feed speeds, layer inter pass temperature, design and details of splice welds if component will be printed in two pieces (or state if will be printed in one piece), areas with additional machine stock, and details for what overhang support material/reinforcement will be used and if and how it is to be removed.

Plan must detail how distortion will be controlled, the regulation of the temperature of the part during printing, and inspection of the part during printing. Following completion of all additive manufacturing and machining of a part, submit Additive Manufacturing Final Build Model File showing final as-built condition of the part, including any support material that remains within the final part after machining, in its native file format.

• During fabrication, Contractor must simultaneously build test towers, to be later used by ERDC, as material testing coupons for tension and Charpy impact toughness.

• The government will inspect the parts at times during fabrication and prior to shipment.

• At final shipping the government will inspect the parts and the shipping container for final acceptance of the parts and shipping methods. The contractor will have all visual and NDT inspections complete and documented for Government review prior to final acceptance.

GOVERNMENT PROVIDED INFORMATION:

See attached CAD files for part geometry:

1. 2D drawings (IWW-1150-A-F_GIWW Brazos River Floodgates 55[4][2])

2. 3D Part Model - 3DHinge.stp

PACKAGING:

• The part must be placed on a strong wooden pallet capable of holding a 2000 lbs. steel object that is approximately 45 inches long. This pallet must be able to be moved by the properly sized forklift truck.

• The Contractor must be required to crate the part/parts for storage using a wooden box cover.

• The part must NOT be oiled for shipping.

• The part must be shrink wrapped in plastic wrap.

• The part must be secured to the pallet using steel banding in enough places to ensure no movement during transportation and storing.

DELIVERY: Shall be made no later than 5 weeks after award by the Contractor as FOB destination to an exact location specified at a later date. Location likely for estimating shipping cost: Crate will be properly labeled and tracked for shipping.

Galveston, TX

*Shipping terms shall be FOB DESTINATION.

PRICING: Quote shall include unit pricing and shipping for 1 sector gear top hinge.

Description Qty Total (including shipping) Sector gear top hinge (As- Printed)