Corpus Christy Army Depot (CCAD)
Chrome plating rack and Know-Mask anodes used for plating horizontal
pins at CCAD.
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.
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.
pins plating with ATC Know-Mask anodes.
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
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).
was highly successful:
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
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).
a loaded shop labor rate of $72 / hour, the projected labor cost
savings from implementation of ATC Know-Mask tooling is $892,080 per
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.
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
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.
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
• Advanced Tooling Corporation •
George Cushnie 434-286-7781 • Randy Taylor 440-632-0572