You might try electroless plating followed by electroplating the resulting coating. I know they do some plastics this way, but beyond that I don't know much about the process.
Kalroy
If you can, find out how the parts are being racked. Quenching at an angle, or even off horizontal can cause warpage and banana bend. But that wouldn't account for the cracking.
Kal
I couldn't find it in Mil handbook 5, ASM Handbook vol 4 (heat treatment), PWA manual, T.O. 1-1A-9, or any of the filler rod guides we have here at Edwards either. 2008, 2024, and 2219 sure, but no 2023.
sorry,
Kalroy
