Lockheed Martin Energy Systems, P.O. Box 2008, Oak Ridge, TN 37831-6192

A -- R&D FOR THE DEVELOPMENT OF TECHNOLOGIES TO LEAD TO LOW COST CARBON FIBER FOR AUTOMOTIVE GRADE STRUCTURAL COMPOSITE MATERIALS DUE 063098 POC Contractual Contact: Guy Leedy, Tel: 423/576-1406, Fax: 423/241-2426, E-mail: G8L@ornl.gov; Technical Contact: Dave Warren, Tel: 423/574-9693, Fax: 423/574-9407, E-mail: WARRENCD@ornl.gov E-MAIL: Click Here To Contact the Contracting Officer Via E-mail, G8L@ornl.gov. Lockheed Martin Energy Systems, inc. acting on-behalf of Lockheed Martin Energy Research Corporation under Prime Contract No. DE-AC05-96OR22464, with the Office of Transportation Technologies (OTT) of the Department of Energy (DOE) is interested in receiving Expressions Of Interest (EOI) for the research and development of low cost materials and methods for producing carbon fibers and other high modulus fibers for automotive applications. R&D programs must have a credible path to fibers that will cost less than $5.00 per pound in quantities of one million or more pounds per year. These fibers will have tensile strengths greater than 400,000 psi, elastic modulus greater than 25,000,000 psi and strain to failure greater than 1%. The OTT, Office of Advanced Automotive Technologies has a multi-year, multi-agency collaborative program conducted in conjunction with domestic automotive manufacturers and suppliers to develop technologies for improving fuel efficiency, reducing emissions and improving industrial competitiveness. One path to achieving these goals is through the incorporation of advanced materials in automotive structures to reduce vehicle weight and thus fuel consumed and emissions released. For every 10% reduction in curb weight a corresponding 6% improvement in fuel efficiency is achieved. Further improvements in efficiency can be achieved by a corresponding downsizing of the powertrain while maintaining equivalent performance in a lighter weight vehicle. Carbon fiber based composites are one class of material under serious consideration for use in future primary automotive structural applications. Carbon fibers offer a significant weight savings potential because of their high strength, high modulus and low density. Studies show that significant use of carbon fiber based composites could be used to reduce body and chassis weight by more than 50%. The most significant obstacle, however, to the widespread use of carbon fiber based composites by the domestic automotive industry is the high cost of carbon fibers in comparison to other potential vehicle structural materials. Fiber cost is also a significant obstacle to the use of these materials in construction and infrastructure applications and cost reducing technologies developed under this program would likely benefit those industries as well. Carbon fibers are currently produced by thermal pyrolysis of a precursor followed by a heat treatment (often coupled with stressing) to obtain the desired properties. The greatest cost factors in carbon fiber production are the high cost of precursors (45-60% of production costs) and the high capital equipment costs (20-35% of production costs). The automotive industry requires carbon fibers in the range of $3.00 to $5.00 per pound for large scale implementation. The industry also needs 25-70 million modulus fibers with strains at failure greater than 1.0%. Other high modulus fibers will also be considered as long as the technical performance and total system accounted costs of using such fibers would be advantageous over $3.00 to $5.00 per pound for carbon fibers. While there are many important technical issues to be resolved before carbon fiber based composites are implemented into primary automotive structures, this EOI seeks information in the following areas only. Funding levels will be determined by project type, merit and available resources. 1. Advanced Precursor Technology: Polyacrylonitrile (PAN) and Pitch (obtained from a variety of substances) are the two most commonly used precursors for production of carbon fibers. Needed are new precursors which have the potential for being converted into carbon fibers at total accounted costs substantially below the cost of current precursors. Proposed precursors may be processed by thermal pyrolysis or by other conversion methods. 2. Advanced High Modulus Fibers: While carbon fiber in the $3.00 to $5.00 range is a leading candidate for future automotive applications, other fibers will also be considered. Fiber development technologies are sought which will yieldperformance levels nearing those of carbon fiber at total accounted costs less than carbon fiber. A detailed cost analysis must be conducted early in any proposed project. 3. Improved Precursor Processing: Current methods for processing Pitch and PAN precursors rely upon thermal pyrolysis of the precursor. The stabilization/oxidation phase of the production process is the most capital intensive and the portion of the production flow that is the major limiting factor to line output speed. Technologies that lead to significant improvements to current production methods, equipment or throughput speeds are sought. 4. Novel Production Methods: Thermal pyrolysis of a precursor is the typical way that carbon fibers are produced. While this has been an effective method for meeting the requirements of aerospace, defense and sporting goods industries, the costs associated with this method are currently prohibitive for higher volume applications. Alternate, methods for producing carbon fiber from Pitch or PAN or other precursors are sought which will either significantly reduce capital investment or greatly increase line output speeds. Non-thermal energy deposition processes will be given preference. EOI Requirements: Ideas for small incremental improvements in equipment or processes are not being sought. Since four separate areas of research are described by this EOI, a physically separate response for each area of research is required. However, two or more areas of research may be combined if strong interfaces or interrelationships can be clearly shown. Please limit responses to 4 or 5 typed pages per research area. Responses must contain the following information: (1) Description of the proposed research, including roles of suppliers, consultants and subcontractors; (2) a critical review of existing and emerging technologies on a world-wide basis that may compete with the proposed technology. The review should conclude that the proposed research is timely, does not duplicate work being pursued elsewhere and is more competitive than existing or emerging technology; (3) a solid technical description of the proposed technologies; (4) a solid economic basis for concluding that implementation of the proposed technology will lead to a significant reduction in carbon fiber costs and supporting analysis or documentation; (5) a Statement of Work and Management Plan including a project schedule, work breakdown structure, budget plan, milestones, and decision points. For truly innovative technologies, a proof of concept phase followed by a clear go/no-go decision point is preferred; (6) a description of all cost sharing commitments which are not required but are preferred; (7) respondents proposed structure for vertical or horizontal teaming/collaboration with co-participants or suppliers (a list of prospective suppliers should be provided); (8) an estimate of the total research and development cost required to reach the stage of technology development at which government funding will no longer be required; (9) the qualification and capabilities of the organizations and individuals responsible for performing the work; (10) evidence of interest in the proposed research by industry; and (11) evidence of the respondent's eligibility to receive financial assistance from the U.S. DOE under Section 2306 of the Energy Policy Act of 1992 (see below). Additional information may be requested during review of the responses. After a thorough review of the responses, a competitive solicitation may be issued. If so, proposal evaluation criteria might include such factors as: (1) technical merit (technical potential for achieving program goals); (2) industry potential (probability for commercial implementation and economic viability); (3) the proposer's research qualifications and capabilities; (4) the proposer's facilities; (5) cost-sharing participation (cost-share of 50% would be the goal); and (6) proposer's team structure [inclusion of HBCUs, MEIs, small and small disadvantaged businesses, minority-owned businesses and an automotive OEM(s)]. Only proposals which are meritorious based upon the solicitation's evaluation criteria and which represent a unique or innovative idea, method or approach would be considered for award. Based on the availability of funds, multiple awards could be made. This EOI infers no commitment to issue a solicitation or to make any award. Any and all costs associated with the preparation of responses to this EOI are the sole responsibility of the respondent. White papers may be submitted prior to response submittal to obtain feedback. Responses to this EOI may be submitted either electronically or by facsimile or by mail to the Contractual Contact listed above. Responses must be received by June 30, 1998. If electronic or facsimile submission is chosen, an original copy of the response(s) must also be mailed. ENERGY POLICY ACT SECTION 2306. LIMITS ON PARTICIPATION BY COMPANIES, A company shall be eligible to receive financial assistance under sections XX through XXIII of this Act only if (1) the Secretary finds that the company's participation in any program under such titles would be in the economic interest of the United States, as evidenced by investments in the United States in research, development, and manufacturing (including for examples the manufacture of major components or subassemblies in the United States); significant contributions to employment in the United States; an agreement with respect to any technology arising from assistance provided under this section to promote the manufacture within the United States of products resulting from that technology (taking into account the goals of promoting the competitiveness of United States industry), and to procure parts and materials from competitive suppliers, and (2) either -- (a) the company is a United States -- owned company; or (b) the Secretary finds that the company is incorporated in the United States has a parent company which is incorporated in a country which affords to United States-owned companies opportunities, comparable to those afforded to any other company, to participate in any joint venture similar to those authorized under this Act; affords to United States-owned companies local investment opportunities comparable to those afforded to any other company; and affords adequate and effective protection for the intellectual property rights of United States-owned companies. (0040)

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