PD.pdf_-__-_02-12-2015.pdf

2/12/2015

Ion Vapor Deposition (IVD) Aluminum Coater Systems

Purchase Description

1. Scope: This document comprises the purchase description for the following equipment: Two (2) Ion

Vapor Deposition (IVD) Aluminum Coater Systems.

1.1. The purchase price shall include the complete systems, delivery, all listed accessories/options, installation, warranty, and training/familiarization

1.2. The contractor or vendor shall provide all materials and labor necessary to deliver and install the IVD aluminum coaters.

1.3. All work shall be completed in accordance with this product description and shall be subject to the terms of the contract.

2. Design:

2.1. The IVD Aluminum Coater Systems shall be new units, complete and ready for immediate operation after installation, acceptance testing and training are completed.

2.2. Products such as prototype units, pre‐production models, or experimental units do not qualify as meeting the requirements specified herein.

2.3. Coater systems shall include all components, parts, and features necessary to meet the performance requirements specified herein.

2.4. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement and repair.

3. Requirements:

3.1. Coater System Details and Characteristics. Each IVD Aluminum Coater Systems shall include the following subsystems and/or characteristics:

3.1.1. Coating chamber. A coating chamber measuring 72 inches in diameter and 144 inches long. The chamber shall be horizontally‐oriented and configured for horizontal loading.

3.1.2. Coating zone. Each coater system shall have a minimum effective coating zone envelope measuring 60‐inches wide (5 feet) by 16‐inches high (1‐1/3 feet) by 120‐inches long (10 feet).

3.1.3. Protective liners. Each coater system shall have stainless steel liners mounted in sections inside the coating chamber. The liners shall protect the chamber interior and interior components from the build‐up of deposited aluminum. The liners shall be easily removable from the chamber to facilitate their cleaning.

3.1.4. Parts Racks. Parts to be coated shall be loaded onto or into stainless steel parts racks/assemblies that are placed in the coating chamber. The coater system shall be capable of using the following types of load racks:

3.1.4.1. A wire‐mesh grid rack from which stationary parts are suspended within the coating zone using J‐hooks or equivalent.

3.1.4.2. A dual‐barrel rotary coating assembly to hold small parts in rotating barrels as the parts are being coated.

3.1.4.3. A rotary parts‐holding rack which allows for the rotation of parts that are mounted on the rack. The coater system must be capable of rotating the parts continuously during coating and rotating them intermittently between coating passes. The rotary parts‐holding rack shall be sized sufficiently so that up to six C‐

130 Rear Barrel Halves (P/N 536385) may be mounted onto the rack and coated simultaneously.

3.1.5. Dual‐Barrel Rotary Coating Assembly. The contractor shall provide two dual‐barrel rotary coating assemblies (four barrels total) with barrels that are a minimum 14 inches in diameter and 48 inches in length. Barrels shall be constructed of perforated stainless steel.

3.1.5.1. The contractor shall provide a floating air dolly to support and transport the dual barrel rotary coating assemblies.

3.1.6. Compatibility with Racks and Dollys. If the coater systems are compatible with the grid rack, rotary parts‐holding rack, floating air dollies and IVD fixtures currently in use at

Robins AFB then no additional racks and/or floating air dollies must be provided.

3.1.6.1. To utilize racks in use at Robins AFB, the rack rails in the coater systems that support the racks should be spaced horizontally 62 inches apart (center‐to‐center) and 72.31 inches vertically above the floor. Rack rail slots should measure 1.25 inches wide to accommodate rack rollers.

3.1.6.2. Floating air dollies used to load grid racks have rack load rails that are 120 inches long, 62 inches wide center‐to‐center, and 72.31 inches high.

3.1.6.3. Floating air dollies used to load rotating barrel racks have rack load rails that are

58 inches long, 62 inches wide center‐to‐center, and 72.31 inches high.

3.1.7. Incompatibility with Racks and Dollys. If coaters systems are incompatible with existing racks, air dollies and fixtures, then the contractor shall provide coater‐system‐compatible floating air dollies, racks, fixtures and/or hangers as necessary as detailed in 3.1.7.1 thru

3.1.7.4 below:

3.1.7.1. For each coater system (i.e. two total grid racks) the contractor shall provide one heavy wire‐mesh grid rack consisting of a grid work to which parts can be hung.

The rack shall provide a coating envelope 60‐inches wide (5 feet) by 16‐inches high

(1‐1/3 feet) by 120‐inches deep (10 feet).

3.1.7.2. The contractor shall provide one (1) air‐ride rack transport dolly for each grid rack (two total transport dollys) to facilitate the loading, handling and transporting of the grid racks. The dollys shall be fully compatible with the grid racks and the IVD coater chamber rack‐holding hardware.

3.1.7.3. The contractor shall provide one rotary parts holding rack. The rack shall be sized sufficiently so that up to six C‐130 Rear Barrel Halves (P/N 536385) may be mounted onto the rack and coated simultaneously. The coater system must be capable of rotating the parts continuously during coating and rotating them intermittently between coating passes. Rotation shall be controllable via the computer control system of the IVD coater.

3.1.7.4. The contractor shall provide one (1) air‐ride transport dolly to facilitate the loading, handling and transporting of the rotary parts holding rack. The dolly shall be fully compatible with the rotary parts holding rack and the IVD coater chamber rack‐ holding hardware.

3.1.8. Doors. The coating chamber shall have full‐access front and rear doors. The front door shall have manual door clamps that prevent the door from moving open but still allow the vacuum seal to break. The rear door shall be accommodating for maintenance purposes.

3.1.9. Door Sight Port. The front door shall have a sight port for viewing the coating process. The sight port shall be metal shielded to minimize coating buildup on the sight glass surfaces.

The sight port shall have a minimum surface area of 100 square inches.

3.1.10. EMT Conduit and Wiring. Each coater system shall include full EMT conduit and wiring for all systems and subsystems.

3.1.11. Vacuum. Each coater system shall have a vacuum pumping system that is capable of creating and sustaining an ultimate vacuum in the 10‐5 Torr range.

3.1.12. Vacuum Pumping System Each coater system shall have a vacuum pumping system that includes:

3.1.12.1. An Edwards Model 1722S (300/1600 CFM) mechanical pump and blower combination (or equivalent) with oil mist separator for mechanical vacuum pump exhaust.

3.1.12.2. A Varian Model NHS‐35 diffusion pump (or equivalent) with rotary vane holding pump.

3.1.12.3. A Poly Cold Cryo‐Pump System (or equivalent) with refrigeration coils and interconnecting tubing.

3.1.13. Safety Interlocks. Each coater system shall have interlocks to shut off power to the following systems when the door is open:

3.1.13.1. High voltage power supply

3.1.13.2. Pressure controller

3.1.13.3. Evaporation system

3.1.13.4. High vacuum valve

3.1.13.5. Vacuum pumping system

3.1.14. High DC Voltage Power Supply. Each coater system shall include a high DC voltage power supply to be used for glow discharge cleaning of the parts. The high voltage controls shall be located in the control console. A timer that monitors the time duration for glow discharge shall be included in the control console. The high voltage shall be interlocked with the vacuum system such that the power supply can be operated at a high vacuum, and be disabled otherwise.

3.1.15. Pressure Control. Each coater system shall be capable of maintaining pressure control during glow discharge and coating cycles.

3.1.16. Gas Backfill System. Each coater system shall include a nitrogen/argon gas backfill system.

3.1.17. Aluminum Evaporation System. Each coater shall include an aluminum evaporation system. The aluminum evaporation system shall include an aluminum wirefeed mechanism with quick disconnect wire feed tube guides. Each wirefeed shall be electrically isolated from ground and from other wirefeeds. The evaporation system shall utilize intermetallic boat‐type sources with individual constant voltage power supplies for each boat. Each power supply shall be individually adjustable for preheat power and run power. Ammeters shall display the current for each boat.

3.1.18. Control System. The control system for each coater system shall include the following:

3.1.18.1. A cabinet mounted PC with color touch screen and control display.

3.1.18.2. An Alan Bradley PLC to perform all furnace sequencing and alarm functions.

3.1.18.3. Ammeters for aluminum evaporators.

3.1.18.4. Ammeter and voltmeter for the plasma power supply.

3.1.18.5. Gauges for the vacuum and thermocouple readouts.

3.1.18.6. Remote access software for diagnostics and troubleshooting.

3.1.18.7. An uninterruptable power supply (UPS) system to prevent abrupt system shutdowns.

3.1.19. Automatic/Manual Control. The control system for each coater system shall allow for both automated and manual control.

3.1.20. Control System Display. The control system shall display from its main menu the following screens:

3.1.20.1. An alarm screen to display all active alarms.

3.1.20.2. A pump control screen from which the pumps may be activated.

3.1.20.3. A monitor cycle screen which displays the operational status of the furnace system and controls to start or stop a process cycle.

3.1.20.4. A recipe edit screen from which you may select, edit, and save recipes for use by the furnace control system and apply values to various set points and process variables.

3.1.20.5. A password‐protected login screen.

3.1.20.6. A manual control screen.

3.1.20.7. A cryopump control screen.

3.2. Electrical System. The existing source voltage at the customer facility is 480 volt, 3‐phase, 60 hertz. The IVD coater systems shall be tolerant of fluctuations of ±10%. The electrical system shall be complete. This shall include any electrical transformers that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused disconnect device shall be utilized on the machine with means of lockout in the off position only.

3.3. Standard Equipment. All standard equipment required for proper operation of the IVD coater systems (such as special tools) shall be furnished. A list of these items shall be provided.

3.4. Nameplate. A nameplate shall be permanently and securely attached to each IVD coater system. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer’s permanent records. The nameplate shall contain the information listed below:

3.4.1. Equipment nomenclature

3.4.2. Manufacturer’s name

3.4.3. Manufacturer’s model number

3.4.4. Manufacturer’s serial number

3.4.5. Power input (volts, total amps, phase, and frequency)

3.4.6. Government contract number

3.4.7. Date of manufacture

3.5. Contractor Reporting. Within 15 days of contract award the contractor shall provide to the government POC an equipment delivery schedule and a listing of all utility requirements for the equipment. The contractor shall provide to the government monthly status updates (due by the 5th of each month) to the delivery schedule. The contractor shall coordinate with the government prior to delivery of any equipment to ensure that the site has been prepared and is ready for receipt of the equipment. (CDRL A001, Contractor’s Progress, Status, and

Management Report, DI‐MGMT‐80227)

3.6. Technical Data. Three (3) hard copies and one (1) electronic copy of technical data shall be provided with the system. Technical data shall contain technical information, specifications, equipment operating instructions, maintenance and servicing instructions (preventive and corrective), and an illustrated inventory parts list that includes spare parts and repair parts listings. All copies of technical data shall be legible and written in the English language. (CDRL

A002, Commercial Off‐The‐Shelf Equipment Manual Requirements, MIL‐DTL‐24784/4C)

3.7. Engineering Drawings. Engineering drawings for system schematics, wiring diagrams, equipment and/or components shall be provided with the technical data. All engineering data shall comply with ASME Y14.100, ASME Y14.34M, and ASME Y14.35M. (CDRL A003, Commercial Drawings/Models and Associated Lists, DI‐SESS‐81003D)

3.8. Installation and Training.

3.8.1. The IVD Aluminum Coater Systems shall be installed by the contractor/vendor’s qualified representative(s) in the government’s designated location in Building 142 at Robins AFB, GA. All items shall be assembled and installed utilizing best commercial practices and manufacturer’s installation procedures. The government shall supply all required utilities within ten (10) feet of the installation site.

3.8.2. The IVD Aluminum Coater Systems are replacing older units that are installed in Building

142 but will be removed prior to installation of the new units. The new IVD units must fit the floor “footprints” as shown in the attached floor diagram (Figure 1). Pumps and power supplies are separated by a wall from the control panel and access side of the IVD chamber. The control panel and access side of the one IVD chamber must fit within area

A1 and its power supply and pump systems must fit within area A2. The control panel and access side of the second IVD chamber must fit within area B1 while its power supply and pump systems must fit within area B2.

3.8.3. In order to minimize disruption of ongoing production, the IVD coater systems shall be delivered and installed one at a time, with the first unit being delivered, installed, proven out and approved for production before delivery of the second unit. Robins AFB will be responsible for site preparation. Upon award of contract, the contractor will coordinate with Robins AFB and determine the delivery date for the first unit and the location of either A1/A2 or B1/B2 as the first system to be installed. Robins AFB will remove one of the IVD units that are being replaced and prepare the site for delivery and installation of the first new unit. Upon delivery, the unit will be installed, final site prep will be completed and all acceptance testing and verification will be conducted and completed.

The unit will then be subject to a 30 calendar day production period to ensure successful capabilities are sustained before the to‐be‐replaced unit is shut down. Prior to delivery of the second unit Robins AFB will shut down and remove the unit to be replaced and will prepare the site for the new unit. The second unit will be delivered, set up, final site prep will be completed, acceptance testing and verification will be conducted and the unit will be brought up to production.

3.8.4. Within 30 days of installation and start‐up, operator and maintenance training will be provided for up to 10 Air Force civilian equipment operators and service technicians by the contractor’s qualified representative at no additional cost to the government. Training shall include a minimum of two (2) days of classroom training (in a government provided facility) and three (3) days of hands on training for the equipment operators. Training for basic troubleshooting and maintenance shall be a minimum of one (1) day of mixed classroom and hands‐on training.

4. Quality Assurance

4.1. Coater System Performance. The coater systems shall be capable of depositing a high purity

(99% plus) aluminum coating to the surfaces of low alloy steel, stainless steel, aluminum alloy, copper alloy and titanium alloy parts in accordance with the requirements of MIL‐DTL‐83488D

(Classes 1, 2, and 3; Types I and II). Acceptance of the coater units is contingent upon the coaters producing acceptable MIL‐DTL‐83488D conforming aluminum coatings.

4.2. Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein except where noted. The Government reserves the right to conduct and/or witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.2.1. Responsibility for Compliance. All items must meet all requirements of Section 3 and

Section 4.

4.3. Test/Acceptance Plan. A complete test/acceptance plan shall be developed by the contractor;

reviewed and modified/approved (as appropriate) by the government contract technical representative; and mutually agreed upon prior to conducting any test. Documentation verifying the acceptance testing and verification shall be provided to the Government. (CDRL

A004, Acceptance Test Plan, DI‐QCIC‐80553A)

4.4. Classification of Inspections. The inspection requirements specified herein are classified as follows:

4.4.1. Final Inspection/Acceptance Test (Destination) (see 4.6)

4.5. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55 degrees F to 100 degrees F and 10 percent to 95 percent relative humidity.

4.6. Final Inspection/Acceptance Test (Destination). Final inspection and acceptance test shall be performed on each IVD System to ensure conformance with this purchase description. The acceptance test shall be performed for each unit only after the IVD system is installed at its final location. The acceptance test shall consist of the examination in 4.7 and all the tests in 4.8.

Each IVD system shall pass the examination, all tests, and the final inspection to be accepted.

4.7. Examination. The IVD systems shall be examined to determine compliance with all requirements of this purchase description.

4.8. Tests.

4.8.1. Operations Test. Each machine shall be operated at no load for a minimum of four (4) hours. Proper operation of all controls, motors, adjusting mechanisms, and accessories shall be verified during the trial period.

4.8.2. Performance Test. The performance test shall be in accordance with and conform to MIL‐

DTL‐83488D. Performance testing and verification shall be performed on‐site at Robins

AFB, GA. Test coupons and test components shall be provided by Robins AFB. The contractor must demonstrate that each IVD Aluminum Coater is capable of producing a

MIL‐DTL‐83488D compliant coating (Class 1, Class 2, and Class 3; Type I and Type II) on test coupons and on C‐5, C‐130 and/or F‐15 aircraft components. Performance testing shall be performed individually for each rack mode (i.e. grid, barrel, and rotary rack). The following requirements utilizing the following cited sections of MIL‐DTL‐83488D shall be used to ensure that each IVD unit meets the Government’s minimum requirements:

4.8.2.1. Appearance. In accordance with MIL‐DTL‐83488D para 3.9.2 the coating shall be smooth, fine grained, adherent, uniform in appearance, and free from staining, pitting, blisters, porosity and other defects. Aluminum nodules on the surface resulting from wire splatter shall not be acceptable on coated parts.

4.8.2.2. Thickness. Coating thickness shall be measured using both test coupons and complicated geometric components. In accordance with MIL‐DTL‐83488D para 4.4.1, test samples shall have the thickness determined by eddy current test, beta backscatter test, micrometer measurements, microscopic test or magnetic tests.

Magnetic test is applicable only to ferrous alloy substrates. Beta Backscatter test shall be made in accordance with ASTM B567. The microscopic test shall be in accordance with ASTM B487. The magnetic test shall be made in accordance with

ASTM B499. The test specimens (coupons) shall be 1 inch by 4 inches by 0.040 inch made of SAE 4130 steel (AMS 6345) or equivalent.

4.8.2.2.1. In addition to coupons, complicated geometric components will be provided by the Government for testing. Where practicable, coating thickness on these components shall be measured directly on the parts.

4.8.2.3. Adhesion Testing. A Bend or Stress Rupture test on metal strips shall be utilized for acceptance determination. The adhesion of the coating shall show no sign of separation from the base metal at the interface when examined at a minimum magnification of approximately four‐diameters. The interface between the aluminum and the base metal is the surface of the base metal before coating. The formation of cracks in the deposit caused by rupture of the base metal that does not result in flaking, peeling or blistering of the deposit shall not be cause for rejection.

4.8.2.3.1. Metal strips approximately 1 x 4 x 0.040 inch, SAE 4130 (AMS 6345) or equivalent shall be used as substrate material for plating adhesion tests for carbon, low and high alloy and stainless steel parts.

4.8.2.3.2. Metal strips approximately 1 x 4 x 0.040 inch, 7075‐T6 (QQ‐A‐250/12) or

2024‐T81 (AMS‐QQ‐A‐250/4) or equivalent shall be used as substrate material for plating adhesion tests for all aluminum alloys.

4.8.2.4. Base Metal Integrity. In accordance with MIL‐DTL‐83488D para 3.10 aluminum base metal parts after coating shall have a Rockwell B hardness change of no more than 3 points. The hardness after coating shall meet the minimum acceptable value for that alloy and temper.

4.8.2.5. Corrosion Resistance. Steel panels approximately 4 x 6 x0.040 inch, SAE 4130

(AMS 6345) or equivalent shall be coated and used for corrosion tests. Test samples shall be corrosion resistance tested in accordance with ASTM B117 to determine conformance to MIL‐DTL‐83488D, para 3.8 requirements. Test samples shall show no evidence of corrosion of the base metal after testing as specified in Table 1 of

MIL‐DTL‐83488D.

4.8.3. Aluminum Purity. Aluminum purity shall be addressed in accordance with MIL‐DTL‐

83488D.

4.8.4. Test Certification. 402CMXG Engineering shall certify all testing on site.

5. Warranty

5.1. All standard warranty provisions shall be included with the bid package but as a minimum shall include one (1) year parts and labor from the time of acceptance for defects in material and workmanship.

6. Data Deliverables/Contract Data Requirements Lists (CDRL):

6.1. CDRL A001, Contractor’s Progress, Status, and Management Report, DI‐MGMT‐80227

6.2. CDRL A002, Commercial Off‐The‐Shelf Equipment Manual Requirements, MIL‐DTL‐24784/4C

6.3. CDRL A003, Commercial Drawings/Models and Associated Lists, DI‐SESS‐81003D

6.4. CDRL A004, Acceptance Test Plan, DI‐QCIC‐80553A

6.5. CDRL A005, Safety and Health Plan, DI‐MGMT‐81580/T

6.6. CDRL A006, Accident/Incident Report, DI‐SAFT‐81563/T

7. Safety Requirements

7.1. The contractor shall establish and maintain a safety and health program in accordance with the elements listed in the Appendix C (Safety Requirements). The contractor shall submit a Safety and Health Plan 10 days after award for review and acceptance by the WR‐ALC/SE (Safety

Office). The contractor shall ensure their Safety and Health Plan addresses, in detail, the items listed in the Appendix C. If task specific procedures are incorporated into a company local document, ensure those procedures are included/attached to the company’s Safety and Health

Plan. Referencing the company’s local procedure/document in the safety plan is not adequate.

If the company’s local procedure/document is not attached; Safety Plan will be returned “Not acceptable”. (Safety and Health Plan CDRL A005 – DI‐MGMT‐81580/T, Contractor’s Standard

Operating Procedures)

7.2. The contractor Safety Plan shall address in detail the items listed in the Contract Appendix C, Part II through Part IV as applicable. For task specific procedures identified in the Contract

Appendix C, the contractor’s internal procedures for those tasks must be identifiable within the submitted Safety Plan or shall be provided in an amendment or addendum to the company’s

Safety Plan. If task specific procedures identified in the Contract Appendix C, are not submitted with the contractor’s Safety Plan, the submitted Safety Plan will be returned as NOT ACCEPTED.

The contractor will have 5 working days to resubmit the Safety Plan, amendment or addendum to address or correct issues identified for non‐acceptance. The WR‐ALC Safety Office will provide acceptance or non‐acceptance of the resubmission within 5 working days of receipt to the COR who will notify the CO.

7.3. Mishap/Incident Reporting. The contractor shall report all mishaps/incidents in accordance with the contract Appendix C. The contractor shall immediately secure the mishap scene and damaged property and impound pertinent maintenance and training records until released by the Government’s Safety Office (WR‐ALC/SE). Such release shall be accomplished through the

CO. The contractor shall cooperate and assist Government personnel in the investigation of the incident and submit an Accident/Incident Report within 24 hours of the accident/incident. The

Contractor shall require all subcontractors to comply with required safety, health and fire standards (CDRL A006, Accident/Incident Report, DI‐SAFT‐81563/T)

8. Additional Requirements

8.1. Prior to delivery of the second IVD aluminum coater system, the first delivered unit must pass all required acceptance testing (operations and performance); in addition, the first delivered unit must demonstrate its performance capability for a period of 30 days. During the performance capability period, the machine must reliably and repeatedly produce acceptable aluminum coatings on production parts as well as testing coupons to be deemed acceptable.

This is to ensure a seamless transition to the new equipment before the second unit is replaced.

8.2. The IVD Aluminum Coater Systems shall include all of the necessary consumables required for initial operation.

8.3. A final walk‐through inspection shall be conducted with the Government Technical

Representative after each installation has been completed. Any components damaged, missing, or improperly installed shall be identified and corrected by the contractor in a timely manner prior to completion of the contract. Only the Contracting Officer is authorized to make changes to the resulting award document and/or contract on behalf of the Government.

8.4. The contractor shall perform the required work during the following normal business hours:

6:30 AM – 3:30 PM, Monday‐Friday. Work performed on weekends and holidays must be approved by the Contracting Officer before work commences. A Government Representative must be present in the event of weekend/holiday work schedule.

8.5. The contractor shall remove all packing materials and residue from the area and properly dispose of off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

8.6. Under no circumstances shall the contractor use Government equipment such as forklifts, ladders, stools, tools, etc. during equipment installation.