A selection of the protective atmosphere eliminating the inter-operational copper plating step in the processing of gear wheels

Purpose: of this paper is modification of the processing procedures of selected components, which would allow one to eliminate the operations of copper plating and copper strip steps. Design/methodology/approach: Along with its technical advantages, helping to satisfy the customers’ needs, the technology of copper plating has one major disadvantage, comprised of the necessity to use highly toxic solutions, and a subsequent need to dispose the toxic wastes. The process of galvanic copper plating is, therefore, an operation unjustified both on ecological as well as on economical grounds. Findings: Application of a fully controlled and reproducible protective atmosphere in the hardening procedure as a replacement approach for a disadvantageous measure of inter-operational copper plating in the production of gear wheels and pinions. Research limitations/implications: The energetic development in automotive and aviation industries have played a significant role in development of modern multitooling technologies in the production of gear wheels [11-14]. As discussed in the works of Dowes and Cooksey [1], Drug and Ghelec [2], Edenhofer [3-5], Hoffmann [8], working components of the bevel and hypoid gear systems in aerospace and automotive industries are usually made of low carbon steels with the gas carburizing operation used for their hardening. Practical implications: The requirements of the aerospace industry do not permit any structural alterations of the surface layer of the processed parts (oxidizing, carburizing or decarburization). Originality/value: Thanks to the specific modifications presented in this work the following achievements were made: lowering the production costs of gear wheels, improvement of environment protection and work conditions by a partial elimination of toxic chemicals.