DOR_Soo Lever Arm Replacement.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 lever arm at Soo Lock.

SPECIFICATIONS:

Lever arm replacement to be fabricated using wire arc additive manufacturing.

Lever Arm Physical Description:

• Lever arm length = 11’-8” ( approx.)

• Lever Arm Weight = 4600 lbs ( approx.)

• Lever Arm Material: 3D Printed Steel – HSLA – High Strength Low Alloy

• Lever Arm Material Ultimate Strength: Su = 105 ksi ( minimum )

• Lever Arm Material Yield Strength: Su = 80 ksi

• Lever Arm Material Percent Elongation: = 20%

• Lever Arm Material Vickers Hardness: HV10 = 280 ( maximum )

• The part must meet the minimum requirements for quality of ASTM A27 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 HSLA steel material meeting the above specifications.

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

• The constructed lever arm 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 (Lever Type A Optimized Unmachined.ipt).

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.

• Lever arm 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

Detroit LRE 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.

• 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 (M-501, M-502)

2. 3D Part Model as printed - Lever Type A Optomized Unmachined.stp

PACKAGING:

• The part must be placed on a strong wooden pallet capable of holding a 5000 lbs. steel object that is 12 feet long and 3 feet wide. 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 8 weeks after award by the Contractor as FOB to an exact location specified at a later date. Location likely for estimating shipping cost: Crate will be properly labeled and tracked for shipping.

St. Louis, Missouri – Metro Area

PRICING: Quote shall include unit pricing and shipping for 1 lever arm.

Description Qty Total (including shipping)

Lever Arm (As-Printed) 1