PWS (Pump).doc

Performance Work Statement (PWS)

High-pressure Common Rail Pump Modification and Demonstration

17 JULY 2024

C.1 Background

The U.S. Army Combat Capabilities Development Command (DEVCOM) Army Research Laboratory (ARL) is seeking to quantify the improvement in durability of high-pressure common rail (HPCR) fuel pumps. ARL and the University of North Texas are conducting a program to select several coatings and materials for integration into HPCR and testing based on the material and coating performance in benchtop tribometer tests.

C.2 Objective

The objective of this contract is fourfold. First, this contract shall provide consulting on the selection of materials and material coatings with DEVCOM ARL, the University of North Texas, and one or more coating manufacturers. Second, this contract shall provide a physical assessment of the pump plunger side loading for the modified coatings under realistic pump internal conditions. Third, the contract shall provide preparation of HPCR fuel pumps for coating of components and/or manufacture components with new materials and reassembly HPCR fuel pumps after coating or manufacture of components. Fourth, this contract shall provide quantification of the improvement in durability of the modified HPRC fuel pumps with low lubricity fuel.

C.3 Requirement

C.3.1 Consulting

C.3.1.1 The Contractor shall consult with ARL for up to 160 hours on the following points of C.3.1 C.3.1.1.1 The Contractor shall consult with ARL and coating manufacturers to discuss the pros/cons of each material to determine the best materials for each of the critical interfaces in the high-pressure fuel pump. Some factors that may influence the decision will be performance of the coatings in coupon experiments, contact conditions of individual interfaces, ease/feasibility of manufacturing, and expected impact of a coating to overall pump performance. The contractor shall be relied upon for their experience in past pump modifications and shall help steer the team towards selection of materials and plans for integration that have the highest probability to survive durability testing defined in C.3.4. During this step the three parties may need to meet several times to create a detailed plan for implementation.

C.3.1.1.2 The Contractor shall aid ARL to determine the requirements for integration of the coatings into HPCR pumps, specifically final roughness, masking, and dimensional tolerance, that need to be maintained by the coating manufacturers. The Contractors’ extensive industry experience will be needed to ensure that coated components meet the quality and tolerance as found in originally manufactured HPCR fuel pumps.

C.3.2 Plunger Side Loading C.3.2.1 The Contractor shall provide data on plunger side load for standard and modified pump polygon materials selected in C.3.1.1.1 to be implemented in C.3.3 under realistic operating conditions as follows:

C.3.2.1.1 Plunger loading under three dynamic pressures up to 1600 bar, C.3.2.1.2 Three operational frequencies up to 33 Hertz (2000 revolutions per minute), C.3.2.1.3 Using geometries/components equivalent to the Bosch CP-3 model to be modified in C.3.3.

C.3.3 HPCR Fuel Pump Preparation C.3.3.1 The Contractor shall prepare up to nine (9) HPCR fuel pumps with three variants of coatings and/or new materials for durability testing. The HPCR fuel pumps will be provided by ARL and are the model Bosch CP-3 with a trigonal cam ring that drives three (3) plungers in three (3) bores connected through a bucket.

C.3.3.2 The Contractor shall prepare up to the following number of fuel pump components for coating or use in the fuel pumps and provide to ARL:

C.3.3.2.1 Surface removal of ten (10) production polygons for thermal spray coating.

C.3.3.2.2 Ten (10) manufactured polygons of alternative heat-treated tool steel, either for coating or for use as-is.

C.3.3.2.3 Thirty manufactured plungers of alternative heat-treated tool steel.

C.3.3.2.4 The Contractor shall await approval from ARL of all modifications before conducting modifications.

C.3.3.2.5 The Contractor shall ensure all components that Contractor manufactures meet standard HPCR tolerances and surface roughness.

C.3.3.2.6 The Contractor shall provide any additional post-processing after coating to deburr. This does not include machining of thermal spray coatings, which will be completed by coating provider.

C.3.3.2.7 The Contractor shall complete modifications within 15 weeks after request by ARL.

C.3.3.3 The Contractor shall reassemble pump components into fully functional HPCR fuel pump within four (4) weeks of receiving coated components.

C.3.3.4 The Contractor shall return two of three pumps of each type of each modified variant to ARL within one (1) week of reassembly.

C.3.3.5 The Contractor shall provide all HPCR fuel pumps and components to ARL that the Contractor received from ARL, both modified and unmodified, by the end of the period of performance. Some fuel pumps will have been run by the Contractor in durability test of C.3.3.

C.3.4 Durability Testing C.3.4.1 The Contractor shall operate one unmodified pump and three modified pumps under the following conditions:

C.3.4.1.1 Operation time up to 1500 hours, C.3.4.1.2 Operation fuel Jet A or F-24 jet fuel that has been clay treated to remove lubricity additives, C.3.4.1.3 Operation speed 2000 revolutions per minute (RPM), C.3.4.1.4 Operation pressure 1400 bar (steady state), C.3.4.1.5 Fuel flow rate of 770 milliliters per minute of high pressure fuel flow, C.3.4.1.5 Regular fuel changes every 100 hours with fuel samples provided to ARL at beginning and end of each 100 hours from a tank of at least ten (10) gallons of fuel, C.3.4.1.6 Fuel filtered with 0.5 (five) micrometer filter, C.3.4.1.7 Datalogging of at least rotational speed, fuel temperature at pump inlet, tank temperature, pump inlet pressure, rail pressure, high pressure flow, return flow, and temperature of return fuel, C.3.4.1.8 Ability to accommodate and provide 120 VAC power to self-contained monitoring equipment from ARL, C.3.4.1.9 And complete fuel flush between fuel pump changes and fuel pump failures.

C.3.4.2 The Contractor shall complete durability testing within eight (8) months of assembling modified pumps

C.3.5 Reporting

C.3.5.1 The Contractor shall provide monthly updates in meetings with ARL.

C.3.5.2 The Contractor shall provide a final report with the results of “C.3.4 Durability testing” identifying the pumps only by alphanumerical designation provided by ARL and the results of “C.3.2 Plunger side loading.”

C.3.6 Past Performance

C.3.6.1 The Contractor shall be able to demonstrate at least 25 years of experience in the design and modification of diesel fuel pumps.

C.3.6.2 The Contractor shall be able to demonstrate past successful HPCR fuel pump modification.

C.3.6.3 The Contractor shall be able to demonstrate past successful HPCR fuel pump testing programs on low lubricity fuel.

C.3.7 Distribution Statement A

Contractor format for the above listed reports is acceptable. All reports/documents must be marked with the following distribution statement:

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Contracting Officer: