Quench Press Hardening with Low Copper Plating. Management and Operation of the DoD Instrumented Factory for Gears
Abstract
Copper plating is used as a carbon stop-off during the carburization and austenitization operations associated with the manufacture of precision gears. The "Low Copper" project's goals were to optimize the thickness of copper needed during carburization, and to eliminate the need to re-plate copper prior to austenitizing, via atmosphere control in a rotary furnace. Traditionally, plating that is 0.001 to 0.003 inch thick is used as a carbon stop-off. Experimentation was aimed at reducing this thickness to between 0.0001 to 0.0005 inch, roughly an order of magnitude thinner. Three designed experiments were performed by IIT Research Institute. Honeywell Engines & Systems of Phoenix, AZ followed the experimentation at IIT Research Institute by performing preproduction tests and additional experiments. Honeywell also prepared a cost benefit analysis to detail and document the projected process savings that could be gained by implementation of the technique. An industry-wide cost-benefit analysis and implementation plan is included. Annual savings realized by pervasive implementation of the technique were estimated at over $1,000,000 per year.
Document Details
- Document Type
- Technical Report
- Publication Date
- Mar 28, 2001
- Accession Number
- ADA435913
Entities
Organizations
- IIT Research Institute