AFFTC/PKAD Directorate of Contracting, 5 S. Wolfe Ave, Edwards AFB, CA93524-1185

66 -- LOW PRESSURE PLASMA SPRAY SYSTEM SOL F0470095RA005 DUE 022295 POC Donna Chesher, Contract Specialist, (805)277-3900 X2255; John Lemacks, Contracting Officer, (805)277-3900 X2253. The Phillips Laboratory at Edwards AFB, California, has a requirement for a low-pressure plasma spray system, using a high-energy, high-velocity plasma to produce monolithic or composite, free-standing, near-net-shaped objects as well as substrate coatings. Characteristics: (1) Vacuum chamber to be government-furnished equipment will be refurbished to include 2-axis sting refurbishment of both axes of motion for which motors and feedback components will be configured to ensure compatibility with CNC motion controller. All mechanical assemblies will be rebuilt, all seals will be replaced with state-of-the-art seals, tested for water flow and cooling, vacuum integrity, motion accuracy and system stability, transfer and main chambers to be cleaned and refurbished, tested for and repair leaks in outer water jacket, tested for vacuum integrity with maximum leak rate of 100 microns per hour and modified to add vacuum pressure transducer to report vacuum pressure. Vacuum manifold to be supplied for which valving is to be controlled from consoles, an automatic pressure control valve, range 5 Torr-200 Torr, will be installed to allow closed loop pressure control at the processing chamber. All components will be cleaned, tested for vacuum leaks performed, tested for vacuum integrity with maximum leak rate of 100 microns per hour. (2) Low-pressure plasma torch hardware, includes: gun motion mechanism capable of positioning plasma spray gun in environments that may include hot dusty conditions, all dynamic penetrations into the vacuum chamber are to be sealed against dust and heat protected. Automatic plasma controller for plasma coating is to have fully automatic process control capable of controlling gas flows, powder delivery rates, water and electrical power, vacuum system functions. Process control is via a full-color CRT monitor which will display programmed process requirement and actual operating conditions, alarm and safety shut-down alert operator if process goes out of range. Controller can be programmed from CRT. Control is from PLC logic controller, with at least 100 memory locations to store process parameters. The controller can be externally commanded by CNC or robot control device. Transfer arc and transfer arc power supply is rated for 250 amps and used to supply power to the transfer arc process for substrate cleaning and heating prior to or during deposition. (3) The entire system, including refurbished chamber, will be shipped to Phillips Laboratory, Building 8424, Edwards AFB, California. (4) The contractor will unpack, install and test the system to ensure proper operation at Edwards AFB facility. (5) The contractor will provide 2 copies of documentation, 2 copies of operating manuals, and training for up to five persons for a duration of up to three days. It has been determined that the required supply is available from only one source and no other type of supply will satisfy the agency's requirements, the AFFTC intends to sole source the requirement with Sulzer Metco, Irvine, California. Telephone requests to be placed on the mailing list will not be honored. See Numbered Note(s): 22. (0020)

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