Projects

Corpus Christy Army Depot (CCAD)

Chrome plating rack and Know-Mask anodes used for plating horizontal pins at CCAD.

Corpus Christi Army Depot (CCAD) operates one of the most modern, largest and busiest Defense Department (DoD) metal finishing facilities. More than 15 different metal finishing processes are present at this facility. Hard chromium plating is one of the most heavily used of these processes; CCAD chromium plates approximately 50 different aircraft parts with a total production load of approximately 4,500 parts per year.

Working under several contracts at CCAD, ATC has developed Know-Mask chrome plating anodes for high production parts that were difficult and labor intensive to mask. Dramatic results have already been achieved. The number of labor hours needed for plating a batch of six horizontal pins has been reduced from 29.13 hours to 11.13 hours (61.8% improvement). The turnaround time has been reduced from 100.13 hours to 51.48 hours (48.6% improvement). At the current production rate of 214 batches per year (1,284 H-pins per) and a shop labor rate of $95/hr. the annual savings are $365,939.

CCAD currently uses Know-Mask anodes to process more than 75% of the hard chrome workload. ATC has also designed and supplied generic racks and conforming anodes to process part with lower production rates.

CCAD conducted a 6-a project to analyze the impacts of Know-Mask anodes on their production (download Army PowerPoint presentation).

Warner Robins AFB

Horizontal pins plating with ATC Know-Mask anodes.

The objective of this project was to design and fabricate Know-Mask anode tooling for two selected parts that are chromium plated, the C-130 propeller hub (hub) and lever support sleeve (sleeve).

The project was highly successful:

• Using existing procedures the overall labor time for plating a single hub is 12.6 hours. Using the ATC Know-Mask tooling, the labor time per hub was reduced to from 12.6 hours to 4.9 hours. The main savings are due to the elimination of wax maskant, reduced tank plating time, and reduced grinding time. The total time required for processing a hub was reduced from 79.1 hours to 50.0 hours (37% reduction).
• Even more dramatic results were observed for the sleeves. Using existing procedures the overall labor time for successfully plating a pair of sleeves is 31.4 hours. Using the ATC Know-Mask tooling, the labor time per sleeve was reduced from 31.4 hours to 4.9 hours. The main reason for the savings is the elimination of rework and wax maskant, reduced tank plating time, and reduced grinding time. The total time required for processing a pair of sleeves was reduced by use of the ATC tooling from 244.7 hours to 50.0 hours (80% reduction).

Using a loaded shop labor rate of $72 / hour, the projected labor cost savings from implementation of ATC Know-Mask tooling is $892,080 per year.

ATC was subsequently awarded a five-year contract for maintenance of the Know-Mask tooling. ATC is also under contract to design and fabricate new tooling for anodizing.

Download WR-ALC report.

Know-Mask anode and rack used for plating the C-130 hub.

ATC Know-Mask anode used for plating C-130 sleeves.

Naval Air Systems Command Depot North Island

The objective of this project was to introduce new electrodeposited hard chrome plating equipment into Naval Air Systems Command (NAVAIR) Depot North Island maintenance activities, including advanced racks, fixtures, and anodes. Work was completed in January 2007. The equipment has been fully integrated into production and the depot is planning to expand use of Know-Mask anodes to other parts.

Private Industry

ATC has successfully completed projects with major aircraft manufacturers and repair facilities involving design and fabrication of Know-Mask anodes for chrome plating commercial and military aircraft parts. ATC also recently assisted a manufacturer of jet engine parts to redesign and retool their chrome plating shop.