Attachment C Technical Specification Plasma Arc Melting System dated July 15 2025.pdf

Technical Specification

Plasma Arc Melting System

Oak Ridge National Laboratory (ORNL, Company) is seeking proposals for the design, supply, and commissioning of a pilot-scale plasma arc melting system intended to support research and development across a wide spectrum of refractory metal alloys. This equipment will be used for experimental melting, casting, and process trials, enabling ORNL to evaluate material performance, optimize melting parameters, and develop new alloy compositions in a flexible laboratory setting.

To meet the needs of ongoing pilot activities, the system must be highly adaptable and capable of operating under diverse processing conditions. It should support various feedstock forms, mold sizes, and melting behaviors, while offering precise control over parameters such as heat input, melt rate, and gas environment. The design must emphasize safety, operational reliability, and ease of maintenance to ensure sustained use across multiple research programs and evolving technical requirements.

Desired Melter Characteristics

• Plasma Torch System o Configured with one or more plasma torches supported by a motion control system capable of programmable and repeatable torch movement.

o Gas delivery manifold should allow for controlled mixing and flow

• Cooling System o Closed-loop water cooling must be provided by the vendor for all heat-intensive components, including the furnace and plasma torch assemblies.

o Integrated manifold and valve control must manage all cooling functions to support continuous operation.

• Material Feeding o Capable of feeding compacted powder or machine turnings, and solid scrap o Systems such as bar feeders or equivalent may be proposed to improve consistency and handling flexibility.

• Ingot Forming and Extraction o Vertical ingot formation using an induction-heated mold zone.

o The system must produce a solid, usable ingot without significant structural or surface flaws o Ingot size capabilities:

Maximum: 100 mm × 100 mm × 1000 mm

Minimum: 50 mm diameter × 1000 mm o Required mold sizes:

60 mm diameter × 1000 mm length

75 mm diameter × 1000 mm length

• Melting Rate o The system must be able to achieve a minimum melt rate of 1000 cubic centimeters per hour under typical operating conditions for refractory metals.

Reference material – Niobium alloy C103

• Operational Safety and Integration o The system should include all framing, enclosures, shielding, and controls necessary for safe operation within a laboratory setting.

o Safety features must align with applicable codes and institutional safety practices.

o Proposals must include on-site installation, commissioning, calibration, operator training, and start-up support.

• Spare Parts and Consumables o A full list of recommended spare parts and consumables must be provided, with pricing and suggested quantities to support early-stage operations.

Utility Requirements

• Power o 480 V, 3-phase, 60 Hz o Total power requirement not to exceed 1200 KVA o No more than three connection points for all system components

• Gases o Helium and argon available at pressures up to 120 psi from facility supply

• Cooling Water o 350 gallons per minute from a tower-based loop (≤110°F) o 80 gallons per minute from municipal supply for emergency and sanitary use

Facility Constraints

• Available Space o Footprint limit: 35 feet (length) × 28 feet (width) × 25 feet (height) o Foundation: 11-inch-thick reinforced concrete slab o The design should avoid the need for below-grade installation or pit construction