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CTMA Project at Corpus Christi Army Depot<br />
<strong>No</strong>-<strong>Mask</strong> <strong>No</strong> <strong>Mask</strong> <strong>Fixtures</strong> <strong>for</strong><br />
<strong>Hard</strong> <strong>Chrome</strong> <strong>Plating</strong><br />
George Cushnie<br />
CAI Resources<br />
Advanced Tooling Corporation
Various Uses<br />
Chromic acid<br />
bath (135 oF) F)<br />
<strong>Hard</strong> deposits,<br />
up to 50 mils<br />
thick<br />
<strong>Hard</strong> <strong>Chrome</strong> <strong>Plating</strong>
Existing DoD<br />
<strong>Hard</strong><br />
<strong>Chrome</strong><br />
<strong>Plating</strong><br />
Technology
Problems with Traditional <strong>Mask</strong>ing<br />
& <strong>Chrome</strong> <strong>Plating</strong> Methods<br />
High labor (plating and<br />
machining)<br />
Long turn-around turn around times<br />
High reject/rework rates<br />
<strong>No</strong>n-uni<strong>for</strong>m <strong>No</strong>n uni<strong>for</strong>m deposits<br />
(increases grinding)<br />
Trees<br />
High energy & pollution rates<br />
Worker exposure issues
<strong>Hard</strong> Cr<br />
Alternatives<br />
(seduction of<br />
low hanging<br />
fruit)
Problems with HCA<br />
<strong>No</strong> single solution <strong>for</strong> all<br />
parts<br />
Multiple processes consume<br />
valuable depot space<br />
Cumulative costs and risks<br />
Most HCA technologies are<br />
years away from full<br />
implementation
<strong>No</strong>-<strong>Mask</strong> <strong>No</strong> <strong>Mask</strong> Approach<br />
Isolate plating process<br />
Elimination of wax, plastic,<br />
tapes, etc.<br />
Con<strong>for</strong>ming anodes<br />
Designed <strong>for</strong> good solution<br />
flow<br />
Easy set-up set up and disassembly;<br />
few or no tools used<br />
Keep worker away from fumes<br />
and lead anodes
CCAD Project Overview<br />
Phase I<br />
Location: Corpus Christi<br />
Army Depot, TX<br />
Time frame: 8/04 – 7/05<br />
7/05<br />
Project procedures:<br />
Project procedures:<br />
Select two parts<br />
Design and test new<br />
fixtures (3-steps) (3 steps)<br />
Delivery of production units<br />
Training<br />
Documentation
Cover Support Sleeve (CH-47)<br />
Outer Bores<br />
(unit cost: $10,378)<br />
Inner Bore
CCAD Cover<br />
Support Set-Up<br />
Lead<br />
Anode<br />
Aluminum Bar<br />
Attaches to Tank<br />
Cathode Bar<br />
Insulating<br />
Block (PVC)<br />
Plastic<br />
<strong>Mask</strong>ing
Old Method of <strong>Mask</strong>ing
Old Method of <strong>Mask</strong>ing
Typical <strong>Plating</strong> Problems
Cover Support Sleeve<br />
Rack/Anodes <strong>for</strong> Outer Bores
Drop-In Fixture <strong>for</strong> Holding Cover<br />
During <strong>Plating</strong> of Outer Bores
Inserting Anode into Outer Bore<br />
Lead Anode
Thumb Screw <strong>for</strong> Attaching Anode
Outer Bore Anodes In Place
Outer Bore After Plate
Inner Bore After Plate
Cover Support Savings at CCAD<br />
(per part basis)<br />
Method Labor<br />
Hrs.<br />
Old<br />
Method<br />
Total<br />
Hrs.<br />
16.0 132<br />
<strong>No</strong>-<strong>Mask</strong> <strong>No</strong> <strong>Mask</strong> 3.0 33.3<br />
Change -81% 81% -75% 75%<br />
Labor includes masking, set-up, and unmasking.<br />
Total time includes masking, plating, unmasking, and baking.
Horizontal Pins Be<strong>for</strong>e <strong>Plating</strong><br />
(CH-47)
<strong>No</strong> <strong>Mask</strong> Method<br />
Old Method
Two H-Pins Ready <strong>for</strong> <strong>Plating</strong>
H-Pins Immediately After <strong>Plating</strong>
Method Labor<br />
Hrs.<br />
Old<br />
Method<br />
H-Pin Pin Savings at CCAD<br />
(per part basis)<br />
Total<br />
Hrs.<br />
4.9 100.1<br />
<strong>No</strong>-<strong>Mask</strong> <strong>No</strong> <strong>Mask</strong> 1.9 51.5<br />
Change -62% 62% -49% 49%<br />
Labor includes masking, set-up, and unmasking.<br />
Total time includes masking, plating, unmasking, and baking.
CCAD Phase 2<br />
Select additional 7 parts <strong>for</strong> no-mask no mask<br />
approach<br />
Generic approach <strong>for</strong> less frequently-<br />
plated parts<br />
Design, test, refine, implement<br />
Time frame: Sept. 2005 to Aug. 2006
Typical CCAD Production<br />
H-Pin Pin – 142<br />
Cover Support – 69<br />
Piston Assy -48 48<br />
Spur gear – 19<br />
Piston (79) – 7<br />
Shouldered shaft – 16<br />
Piston (74) – 6<br />
Piston (80) - 6<br />
400 Parts/Mth.<br />
Gear Assy – 9<br />
Upper Piston – 5<br />
Flange – 3<br />
Sprocket – 2<br />
Aft Rotor Shaft – 1<br />
Support <strong>No</strong>. 4 – 1<br />
Gear input – 1<br />
Line bearing - 0
Piston Assembly
Pistons<br />
79/80
Shouldered<br />
Shaft
Static<br />
Support
Piston 74
<strong>No</strong>rth Island – CTMA Project
Remaining 25% of Parts<br />
Supply generic racks and con<strong>for</strong>ming<br />
anodes<br />
Teach platers how to evaluate/approach<br />
parts<br />
Teach new masking skills<br />
Plate using 2-bus 2 bus bar configuration
Generic Anodes
Static Support
Close-ups Close ups of inner and outer ID<br />
bore areas<br />
Inner bore area Outer bore area
3-Bus Bus Bar Set-up Set up
2-Bus Bus Bar Set-up Set up
CCAD Phase I:<br />
CTMA Works!<br />
Various misc. purchases<br />
Equipment contract (new/refurbish)<br />
CCAD Phase II:<br />
CCAD purchased static support anode set<br />
Other:<br />
Technical services contract
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