Appendix A - Alternative_Cladding_Technical Specification_RFP 964171.pdf
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- Attached to
- MITR Chemically Milled Plate
- Solicitation number
- 0000964171
- Issued by
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Department of Energy
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This is a Technical Specification appendix to Request for Proposal 964171 issued by Battelle Memorial Institute, Pacific Northwest Division, operator of the Pacific Northwest National Laboratory for the U.S. Department of Energy. The specification covers plate fabrication components for the United States High Performance Research Reactor project, which is converting research reactors to use High Assay Low Enriched Uranium fuel. The contractor must produce aluminum cladding plates with pockets that will encapsulate U-10Mo foils and undergo hot isostatic processing for diffusion bonding.
The deliverables include three quantities of 50 pocket plates each in 6061-T6 aluminum at thicknesses of 0.009", 0.012", and 0.015", plus associated tooling for each thickness variant (items 4-6). The contractor must perform non-recurring engineering and tooling design as needed, present tooling design and simulation results prior to fabrication (a hold point), and produce first articles for Battelle evaluation. Proposed production techniques may include photochemical milling, spark electro-discharge machining, or laser pocket etching. All products must meet ASTM B209-14 specifications for aluminum sheet and plate, comply with ISO/IEC Standard 17025:2017 for laboratory accreditation, feature smooth surfaces free of defects, have all sharp corners broken, and be individually vacuum sealed and packaged in 4,000-pound maximum fiber-enclosed skids. Required submittals include material certifications from an accredited laboratory, certificates of conformance, non-conformance reports, and contractor data transmittals. Battelle's technical staff may witness production, and the contractor should preferably maintain National Aerospace and Defense Contractors Accreditation Program certification. Final acceptance requires shipment of intermediate products and disposition of all contractor data submittals and non-conformance reports.
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Appendix A – Technical Specification MITR HIP Can Study and Plate Feedstock Revision 0
Request for Proposal 964171
September 10, 2026
I. GENERAL
A. Background
Battelle Memorial Institute, Pacific Northwest Division (Battelle), operator of the Pacific Northwest National Laboratory (PNNL) for the U.S. Department of Energy, is seeking a Contractor to Plate Fabrication components. The United States High Performance Research Reactor (USHPRR) project is focused on converting the few remaining research reactors in the United States to High Assay Low Enriched Uranium (HALEU). This conversion requires a new high density fuel form. The selected fuel is U-10Mo foils encapsulated into aluminum cladding. The cladding is diffusion bonded to the fuel foil with a hot isostatic process (HIP).
Currently the cladding is mechanically milled from aluminum sheets. Battelle is researching alternatives to produce these plates. Currently Battelle is exploring photochemically milled pockets (the plate can be laser or waterjet cut). Spark electro-discharge machined (EDM) pockets may be proposed, items 4-6 would cover the tooling needed for spark EDM. Laser pocket etching may also be proposed.
TABLE I Cladding (Intermediate Products)
Item No Item Description Material Quantity 1 C66T03V0 0.009" Pocket Plate 6061-T6 Aluminum 50 2 C66T02V0 0.012" Pocket Plate 6061-T6 Aluminum 50 3 C66T01V0 0.015" Pocket Plate 6061-T6 Aluminum 50 4 0.009" Pocket Plate Tooling 1 5 0.012" Pocket Plate Tooling 1 6 0.015" Pocket Plate Tooling 1
B. Work Included
a. The Offeror shall perform the non-reoccurring engineering and tooling design required for items 4, 5, 6 if needed.
b. The Offeror shall produce first articles per Table 1 for Battelle evaluation.
c. The Offeror may propose multiple production techniques for evaluation.
C. Hold Points
a. The Offeror shall present the tooling prior to first article fabrication, as required per Section
II Products under Sub Section D – Submittals.
II. PRODUCTS
A. Intermediate Products The Offeror shall ship Battelle intermediate product according to Table I. Each component shall be individually vacuum sealed and packaged per the associated drawings.
B. Applicable Codes, Procedures, and References
a. ISO/IEC Standard 17025:2017, General requirements for the competence of testing and calibration laboratories.
b. ASTM B209-14, Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate.
C. Requirements
a. Product Dimension and Tolerance as required on drawings.
b. Inspections (Workmanship) of intermediate product.
a) Surface to be smooth and free from pits, dents, scratches, cuts and foreign material.
b) Break all sharp corners unless otherwise specified.
c. Packaging
a) The items shall be packaged in 4,000 lb maximum fiber-enclosed skids with wooden sides and battens.
d. Identification - Each plate and sheet shall be marked per drawing unless otherwise agreed upon by Battelle.
D. Submittals
a. Non-reoccurring engineering presentation
a) The Offeror shall present their tooling design and results of simulations prior to fabrication of tooling.
b. Material certification via PDF
a) From an accredited ISO/IEC Standard 17025:2017 laboratory.
c. Certificate of Conformance for all items.
d. Non-conformance reporting.
The Offeror shall provide for Battelle’s approval any non-conformances that occur at any step of the processing.
III. EXECUTION
A. The Offeror shall develop HOLD POINTS
a. The Offeror shall not proceed with fabrication of the intermediate products until the tooling design is presented.
B. Contractor Surveillance and Audit:
a. It is strongly preferred that the Offeror has an established and maintained National Aerospace and Defense Contractors Accreditation Program certification.
b. Battelle's Acquisition Quality Support program will evaluate the Offeror’s quality program.
c. Battelle technical staff may witness the intermediate product production.
C. Contractor Data Submittal
a. The Offeror can use their own form/template for data submittals.
b. The Offeror may request a template for a contractor data transmittal from Battelle.
D. Non-Conformance Reporting
a. The Offeror may use their own form/template for non-conformance reporting.
b. The Offeror may request a template from Battelle.
IV. FINAL ACCEPTANCE
The final acceptance criteria are:
A. Shipment of intermediate products B. Disposition of all Contractor Data Submittals
a. Offeror provided certificate of conformance
b. Offeror or provided material certification reports
c. Offeror or provided inspection report
C. Disposition of any/all non-conformance reports
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