Implementation of Innovative Hard Chromium Plating Tooling at Corpus Christi Army Depot – Phase I

NCMS Project #: 140384

Problem:

Depot maintenance cycle time has become a high profile issue. Long cycle times adversely affect weapon system and spare parts availability.
Hard chrome plating processes create bottlenecks at depots, limiting throughout and lengthening cycle time.
Intricate masking processes and hand grinding requirements are labor intensive and put high demands on skilled craftsmen.

Benefit:

Availability: 200% increase in plating equipment capacity; resulted in weapon systems out the door faster.
Cost Savings: Annual labor savings of $1.1M; 83% decreased labor cost/part.
Reliability: Improved process control resulted in significant rework reduction; 17% on one part & 46% on another.
Cycle Time: Reduced individual part turnaround by an average of 60%; production capable of meeting demand – previously impossible!
Safety: Worker exposure to hexavalent chromium vapors reduced 50%.

Solution/Approach:

A new approach to anode design avoids the needs for masking, while creating plating conditions that optimize current density and electrolyte flow for each individual part.
Specialized tooling and rack fixtures were installed on critical parts.
The new tooling resulted in:
- Reduced labor for masking
- Faster plating times
- More uniform chromium deposits.

DOD Participation:

Industry Participation: