Appendix A - Aluminum_Specification - RFP 958487.pdf

Appendix A: Technical Specification - High Purity Aluminum Request for Proposal 958487

Revision 0 Dated August 6, 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 provide high purity aluminum sheet, plate, and bar as an intermediate product. Commercial Off the Shelf (COTS) aluminum per ASTM B209-21 Standard Specification for Aluminum and Aluminum Alloy Sheet and Plate may have unallowable impurities. Specifically, this specification is for aluminum that is low in the following impurities (above standard COTS impurities).

TABLE I Chemical Composition

Element Minimum wt. % Maximum wt. % Trace Elements

Gallium 0.00 0.04 Lithium 0.00 0.008

Cadmium 0.00 0.003 Boron 0.00 0.001 Cobalt 0.00 0.001

Other Elements - -each 0.00 0.02 total 0.00 0.15

B. Work Included

a. The Contractor shall perform the necessary non-reoccurring engineering required to produce 6061T-6 meeting the chemical composition identified above.

i. This shall be documented in a report

b. A lot of the alloy is defined as an aluminum alloy that has been produced using the same raw materials and processed in a single time.

i. A lot may contain one or more aluminum ingots/billets/forgings that are produced from a common melt.

c. After the non-reoccurring engineering is completed, the Contractor shall make at least 5 tons of alloy to be processed according to Table II.

d. After the alloy has a vendor or 3rd party laboratory approved material certification for impurities, the Contractor shall fabricate the intermediate products identified in Table II, or Battelle approved alternative intermediate products.

C. Hold Points

a. Prior to processing the intermediate products in Table II, the impurity analysis needs to be completed, certified, and the submittal accepted.

b. Prior to shipment, the intermediate products shall be certified to meet the tensile and ASTM requirements.

II. PRODUCTS

A. Intermediate Products The contractor shall ship Battelle intermediate product according to Table II. The contractor may suggest cost or quality alternatives to the Intermediate products below. Table III is provided for information only to help identify the final aluminum sizes that are used in the fabrication process.

Battelle will accept via a vendor submittal form for any agreed upon alternatives to the Table II Intermediate Products.

Some examples of the suggestions are:

• Combining the 0.125 diameter and 0.75 diameter round stock into a single 0.75 diameter with a quantity of 14 (i.e. if the setup costs exceed the cost for the smaller round stock).

• Combining the 0.125, 0.75 diameter round stock with the 3.5 x 1.00 rectangular bar (i.e.

if there is savings in set up cost savings). Battelle would then saw cut the rectangular bar and turn rectangular pieces into round parts.

• Recommended different lengths of stock/sheet for transportation and storage

TABLE II Intermediate Products

Description Quantity Length (ft) Width (in) Thickness (in) Estimated Mass (lb)

Round Stock 10 12 0.125 dia n/a 18 Round Stock 4 12 0.75 dia n/a 255

Rectangular Bar Stock

100 12 3.5 0.25 1260

Rectangular Bar Stock

25 12 3.5 1.00 1260

Rectangular Bar Stock

20 12 4.5 3.5 4536

Sheet 110 4 8 12 gauge (0.08”) 3960 Sheet 600 4 8 18 gauge (0.04”) 10,800

Total mass 36,850

TABLE III Final Products FOR INFORMATION ONLY Description Length (in) Width (in) Thickness (in)

Pin 3.25 0.125 dia n/a

Description Length (in) Width (in) Thickness (in) Roller 1 0.75 dia n/a

Side Plates 23 – 60 3.5 0.25 Combs 0.25 – 0.125 3.5 1.00

End Fittings 4 – 9 4.5 3.5 Sheet 67 8.25 12 gauge (0.08”) Sheet 41 6.25 18 gauge (0.04”) Sheet 30 6.75 18 gauge (0.04”) Sheet 41-67 8.25 18 gauge (0.04”)

B. Applicable Codes, Procedures, and References

a. ASTM B209-21 Standard Specification for Aluminum and Aluminum -Alloy Sheet and

Plate

b. ANSI H35.2:2024-Dimensional Tolerances for Aluminum Mill Products

c. AMS4027P Aluminum Alloy, Sheet and Plate Solution and Precipitation Heat Treated

d. ISO/IEC Standard 17025:2017, General requirements for the competence of testing and calibration laboratories

C. Requirements

a. Chemical Composition

The chemical composition shall meet the requirements listed in Table I of this specification in addition to associate American Society for Testing and Materials (ASTM) specification requirements. Actual analysis from the melt for the chemical elements listed in Table I shall be made and the results shall be certified that they meet the requirements of this order.

Copies of the certified analysis shall be furnished to Battelle. The certified analysis must include confirmation that the maximum weight percent of each specified trace element, and other trace elements and total trace elements do not exceed the maximum values listed in Table I.

Chemical composition shall be per lot of the alloy. Chemical composition is not required for intermediate products sharing a common lot of the alloy.

b. Product Dimension and Tolerance

a) Product dimensions listed in Table II of this specification.

b) Dimensional tolerance per ANSI H35.2 listed in Table III

c. Temper

a) All coils shall be furnished in a T6 temper.

b) All bar stock shall be furnished in T651 temper.

d. Edge Treatment

a) All sheet and plate edges shall be produced by shearing or sawing.

e. Inspections (Workmanship) of intermediate product

a) Sound workmanship per AMS4027 enforced.

b) Surface to be smooth and free from pits, dents, scratches, cuts and foreign material.

c) After heat treatment, each bar, sheet, or plate shall be inspected to determine whether blisters are present on the surface. A single blister 1/8” diameter or larger needs Buyer approval for disposition (cut out and the immediate area around the blister scrapped).

d) The contractor shall provide an inspection report for the visual inspection.

f. Tensile Properties

a) Results of all tensile properties, including yield strength shall be furnished to Purchaser.

b) All tensile properties shall be per ASTM B209.

c) All tensile properties shall be measured for intermediate product per lot

g. Packaging

a) The items shall be packaged in 4,000 lb maximum fiber-enclosed skids with wooden sides and battens.

h. Identification - Each plate and sheet shall be marked using stencil or other means, as near both ends as possible with

a) Type of Material

b) Lot Number

c) Manufacturers name and/or identification symbol

i. Welding

a) No welding or weld repair on the supplied material is permitted.

D. Submittals

a. Non-reoccurring engineering report

i. Electronic PDF report provided prior to creation of the first lot of alloy. The Contractor will provide their technical approach for the alloy meets the impurity requirements.

b. Lot of Alloy Impurity Analysis

i. Impurity analysis via electronic PDF.

ii. Representative sample of alloy 1 pound in mass.

c. Intermediate Product

i. A representative sample 12 inches long (width and thickness are determined by the intermediate product dimensions) for each lot of each intermediate product (bar/coil) shall be furnished to Battelle for 3rd party analysis.

ii. Electronic PDF with results of tensile tests for each lot of each intermediate product.

iii. Electronic PDF certificate of conformance for each lot of each intermediate product.

iv. Electonric PDF copy of the visual inspection report (post heat treatment).

E. Inspections, Tests, and Hold Points:

a. The Contractor shall provide the results of the impurity analysis and the representative sample to Battelle for 3rd party analysis prior to starting fabrication of the intermediate products.

a. Battelle will accept or reject the submittal in 3 business days of receipt of the report.

b. The Contractor shall provide the results of the tensile tests prior to shipment of the intermediate products.

a. Battelle will accept or reject the submittal in 3 business days of receipt of the report.

c. The inspection report and certification of conformance may be provided at shipment.

d. Non-conformance reporting.

The contractor shall provide for Battelle’s approval any non-conformances that occur at any step of the processing.

III. EXECUTION

A. The Contractor shall develop HOLD POINTS

a. The contractor shall not proceed with fabrication of the intermediate products until the impurity analysis is reviewed and accepted by Battelle.

b. The contractor shall not ship the intermediate products until the tensile test submission is accepted.

B. Contractor Surveillance and Audit

a. It is strongly preferred that the Contractor has an established and maintained National Aerospace and Defense Contractors Accreditation Program certification.

b. Battelle's Acquisition Quality Support program will evaluate the Contractor’s quality program.

c. Battelle technical staff may witness the sample taking during the alloy process and/or the intermediate product production.

C. 3rd Party Analysis

a. The Contractor shall provide 3rd party analysis results for impurities and tensile tests

b. The Contractor may do in-house testing in addition to the 3rd party testing

c. 3rd Party testing shall be performed by an accredited ISO/IEC Standard 17025:2017 laboratory.

i. American Association for Laboratory Accreditation, International Accreditation

Service, or Battelle approved alternative service.

D. Vendor Data Submittal

a. The vendor can use their own form/template for data submittals.

b. The contractor may request a template for a vendor data transmittal from Battelle.

E. Non-Conformance Reporting

a. The contractor may use their own form/template for non-conformance reporting.

b. The vendor may request a template from Battelle.

IV. FINAL ACCEPTANCE

The final acceptance criteria are:

A. Shipment of intermediate products B. Disposition of all Vendor Data Submittals

a. Contractor provided certificate of conformance

b. Contractor provided certified impurity analysis

c. Contractor provided certified tensile test results

d. Contractor provided inspection report

C. Disposition of any/all non-conformance reports