VISVESVARAYA TECHNOLOGICALUNIVERSITY
JNANASANGAMA, BELAGAVI–590018
INTERNSHIP REPORT
A report submitted in partial fulfillment of the requirements for the Award of Degree of
BACHELOR OF ENGINEERING
In
MECHANICAL
ENGINEERING
Internship Carried Out at
HAL FOUNDRY AND
FORGE DIVISION
BANGALORE COMPLEX
SubmittedBy
DHANUSH K
1GD19ME003
DEPARTMENT OF MECHANICAL ENGINEERING
Gopalan College of Engineering and Management
181/1,181/2,Seetharampalya,Basavanagara
HoodiBangalore–560048
2022-23
GOPALAN COLLEGE OF ENGINEERING AND MANAGEMENT
BANGALORE-560048
Department of Mechanical Engineering
CERTIFICATE
This is to certify that the “Internship report” submitted by Mr.Dhanush k (1GD19ME003)
in partial fulfilment for the award of the Bachelor of Engineering in Mechanical Engineering of
the Visvesvaraya Technological University, Belagavi during the year 2022-23 carried outduring
21 September 2022 to 20 October 2022.
The report is approved since it satisfies the academic requirement prescribed for Bachelor of
Engineering
in
Mechanical
University,Belagavi.
Engineering
of
the
Visvesvaraya
Technological
ACKNOWLEDGEMENT
Foremost, we are thankful to our parents for having blessed us throughout our life, and to
have given us everything we have ever wanted.
We wish to express our gratitude to Director Dr. C Prabhakar, General Secretary, Gopalan
Foundation for providing us an opportunity in fulfilling our cherished desire of reaching academic
goals.
With utmost humbleness we express our sincere thanks to Dr. Basavaraju C, Principal,
GCEM, Chief Administrator, GCEM.
We express our sincere thanks to Dr.Natarajan.T , Professor and Head of the Department,
Mechanical Engineering, GCEM
We express our deepest thanks to the internship coordinator Mr. Lokesh M, Assistant
Professor, ME GCEM for organizing, managing, and helping out with the entire process.
If we have missed anyone who is directly or indirectly helped us in his endeavor, it is
totally unintentional.
ABSTRACT
Hindustan Aeronautics Limited (HAL), A Defense Public Sector Unit is a premier global
aerospace company. HAL has expertise in the areas of Design, development, Manufacture and
Maintenance of Light Aircraft, Trainers, Combat Aircraft, Helicopters, Commercial Aircraft, Jet engines,
Aircraft Systems and Equipment, Avionics and aerospace Structures. The Manufacturing divisions are
fully backed by design centers for R&D support.
The major on-going indigenous development programs are the Light Combat Aircraft (LCA) MK
1A, Light Combat Helicopter (LCH), Light Utility Helicopter (LUH), Basic Turboprop Trainer HTT 40
& Indian Multi Role Helicopter (IMRH). Design and Development of HTFE-25 and HTSE- 1200 engines
have also been taken up.
Current upgrade programs include Jaguar DARIN-III upgrade, Mirage upgrade and Hawki. In
addition to the platforms, various Technology development projects have also been launched to increase
self-reliance in critical areas like the Aircraft Display systems, Mission Computers, Automatic Flight
Controls for Helicopters and Aircraft Accessories & Avionics.
There are 21 Production Units and 10 R&D Centers
BANGALORE COMPLEX,
•
Aircraft Division
•
IMGT Division
•
Engine Division
•
Airport Service center, Division
•
Overhaul Division
•
Foundry and Forge Division
•
Aerospace Division
•
LCA- Tejas Division
•
Facilities Management Division
MIG COMPLEX,
•
Aircraft Division, Nasik
•
Aircraft Overhaul Division, Nasik
•
Engine Division, Koraput
•
Sukhoi Engine Division, Koraput
ACCESSORIES COMPLEX,
•
Transport Aircraft Division, Kanpur
•
Accessories Division, Lucknow
•
Avionics Divisions, Hyderabad
•
Avionics Division, Korwa
HELICOPTER COMPLEX,
•
Helicopter Division, Bangalore
•
Helicopter MRO Division, Bangalore
•
Barrack pore Division, Kolkata
•
Aerospace Composites Division
R&D CENTERS
•
Aircraft Research & Design Centre, Bangalore
•
Aero Engine Research & Design Centre, Bangalore
•
Rotary wing Research & Design Centre, Bangalore
•
Strategic Electronics Research & Design Centre, Hyderabad
•
Aircraft Upgrade Research & Design Centre, Nasik
•
Aerospace Systems & Equipment Research & Design Centre, Lucknow
•
Transport Aircraft Research & Design Centre, kanpur
•
Gas Turbine Research & Design Centre, Koraput
•
Mission and Combat System research & Design Centre, Bangalore
•
Central Materials & Processes Laboratory, Bangalore
TABLE OF CONTENTS
Certificate
Acknowledgment
Abstract
Table of Contents
Table of Figures
List of Tables
Chapter1–Introduction
1.1 History
1
Chapter2 – Overview of Foundry and Forge Division
2.1 Mission
3
Week 1 Workshops
Chapter3 – Powder Metallurgy Shop
Bleeding
5
Compaction
5
Sintering
6
Finishing
6
Chapter4 – Ferrous Foundry
7
Chapter5 – Non-Ferrous Foundry
Aluminum Foundry
Magnesium Foundry
9
10
Week 2 Workshop
Chapter6 – Pattern Shop
12
Chapter7–Rubber Shop
15
TABLE OF CONTENTS
Chapter8 – Ring Rolling Shop
17
Week 3 Workshops
Chapter9 – Precision Foundry (Investment Casting)
21
Chapter10– General Forge
24
Chapter11 – Die Shop
27
Week 4 Workshops
Chapter12 – Machine Shop
28
Chapter13 – Precision Forge
29
Chapter14– Shape Memory Alloy (SMA)
32
Chapter15 – Development Department
35
Week 5 workshops
Chapter16–Quality Control Department, Marketing Department
16.1
Dye penetrates testing
38
16.2
Radiography
38
16.3
Eddy Current Testing
38
16.4
Ultrasound Testing
38
16.5
Magnetic Particle testing
39
Chapter17 – Stores
40
Chapter18 – CMPL (Central Material Processing Lab)
Chemical section
42
TABLE OF CONTENTS
Calibration Section
43
Non-Destructive Test section
44
Metallurgical section
45
Mechanical Testing section
45
Research and Development
Chapter19 – Conclusion
46
47
LIST OF FIGURES
Sl . no
Description of Figures
Page.no
1.
Fig3.1 Process Diagram- Powder Metallurgy Shop
6
2.
Fig5.1 Aluminum based Casted product
11
3.
Fig5.2 Magnesium Alloy die casting Part
11
4.
Fig8.1 Process Diagram
19
5.
Fig8.2 Process Diagram – Ring Rolling Shop
20
6.
Fig9.1Green wax used in the models of Lost Wax Investment casting
23
7.
Fig9.2 Cold Wax Investing Casting
23
8.
Fig9.3 Schematic diagram of Investment Casting
23
9.
Fig 10.1 Closed and Opened Die Forging
25
10.
Fig 10.2 Heating Treatment
26
11.
Fig13.1 Aero engine Airfoil
31
12.
Fig15.1 TypicalProcessflow
36
LIST OF TABLES
Sl.no
1.
Description of Table
Table18.1 Functions of central materials and processes laboratory
Page.no
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CHAPTER 1
INTRODUCTION
Hindustan Aeronautics Limited (HAL) is an Indian state-owned aerospace and defense
company headquartered in Bangalore, India. It is governed under the management of the
Indian Ministry of Defense.
The government-owned corporation is primarily involved in the operations of the aerospace
and is currently involved in the design, fabrication and assembly of aircraft, jet engines,
helicopters and their spare parts. It has several facility centers across India including Nasik,
Korwa, Kanpur, Kora put, Lucknow, Bangalore, Hyderabad and Kasaragod. The HAL HF24 Marut fighter-bomber was the first fighter aircraft made in India.
1.1 HISTORY
The history and growth of Hindustan Aeronautics Limited is synonymous with the growth
of Aeronautical industry in India for more than 79 years.The Company which had its origin
as Hindustan Aircraft Limited was incorporated on 23 Dec 1940 at Bangalore by Shri
WalchandHirachand, a farsighted visionary, in association with the then Government of
Mysore, with the aim of manufacturing aircraft in India. In March 1941, the Governmentof
India became one of the shareholders in the Company and subsequently took over its
management in 1942. In collaboration with the Inter-Continental Aircraft Company of USA,
the Company commenced its business of manufacturing of Harlow Trainer, Curtiss Hawk
Fighter and Vultee Bomber Aircraft.
In January 1951, Hindustan Aircraft Limited was placed under the administrative control
of Ministry of Defense, Government of India.
The Company had built aircraft and engines of foreign design under license, such asPrentice,
Vampire & Gnat. It also undertook the design and development of aircraft indigenously. In
August 1951, the HT-2 Trainer aircraft, designed and produced by the company under the
able leadership of Dr. V.M.Ghatge flew for the first time. Over 150 Trainers were
manufactured and supplied to the Indian Air Force and other customers. Withthe gradual
building up of its design capability, the company successfully designed and developed four
other aircraft i.e. two-seater 'Pushpak' suitable for flying clubs, ’Krishak' for Air
Observatory Post (AOP) role, HF-24 Jet Fighter '(Marut)' and the HJT-16 Basic Jet
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Trainer '(Kiran)'.Meanwhile, in August 1963, Aeronautics India Limited (AIL) was
incorporated as a Company wholly owned by the Government of India, to undertake
manufactureof MiG-21 aircraft under license. Factories were setup at Nasik (Maharashtra)
& Kora put (Odisha). In June 1964, the Aircraft Manufacturing Depot which was set up in
1960 at Kanpur as an Air Force unit to produce the Airframe for the HS-748 transport aircraft
was transferred to AIL. Soon thereafter, the Government decided to amalgamate Hindustan
Aircraft Limited with AIL so as to conserve resources in the field of aviation where the
technical talent in the country was limited and to enable the activities of all the aircraft
manufacturing units to be planned and coordinated in a most efficient and economical
manner.
Amalgamation of the two companies i.e. Hindustan Aircraft Limited and Aeronautics India
Limited was brought about on 1st Oct 1964 by an Amalgamation Order issued by the
Government of India and the Company after the amalgamation was named as "Hindustan
Aeronautics Limited (HAL)" with its principal business being design, development,
manufacture, repair and overhaul of aircraft, helicopters, engines and related systems like
avionics, instruments and accessories.
In 1970, a separate division was set up exclusively for manufacture of 'Chetak' and 'Cheetah'
Helicopters in Bangalore under license from M/s SNIAS, France. A new division was also
established to manufacture aircraft instruments and accessories at Lucknow. License
agreements were entered into with M/s Dunlop of U.K. for Wheels and Brakes, Dowty for
under carriages and Hydraulic equipment andNormalAir Garret for cabin air pressurization
and air-conditioning equipment, Smiths of UK, SFENA and SFIM of France for panel
instruments and Gyros, MartinBaker of UK for ejection seats and Lucas for engine fuel
systems; for fitment on Marut, Kiran, Ajeet, Chetak, Cheetah and Jaguar. Similar type of
arrangement was agreed with USSR authorities for manufacture of accessories for MiG-21
series of aircraft.
Design and Development of Basant agricultural aircraft was undertaken between 1970 and
1974 and design and development of Ajeet, an improved version of Gnat, was undertaken
between 1972 and 1980. In 1976, projects were sanctioned for design & development of the
HPT-32 elementary piston engine trainer, Kiran MK II (an improved version of Kiran MK
I / IA) and Ajeet Trainer as well as for Advanced Light Helicopter.
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CHAPTER 2
OVERVIEW OF FOUNDRY AND FORGE DIVISION
The Foundry & Forge Division was established in 1974. The Division's facility, set up on a lush
expanse of 32 acres, manufactures Castings, Forgings, Rolled Rings, Shape Memory Alloy
Products instead of Shape Memory Alloy Ferrules, Brake pads and Rubber Productsfor
critical applications for the Aeronautics, Space, Defense, Locomotive, Earth mover and other
industries. Advanced Technology, Quality and Reliability and a highly skilled workforce have
enabled the Division to turn out fail safe components for vital applications in meeting the
exacting needs of every customer. Foundry & Forge Division, besides catering to its sister
Divisions, supplies products to various domestic customers as well as global Aircraft /Aeroengine primes and Aircraft System manufacturers.
The Division was a pioneer in obtaining AS9100C and NADCAP approvals. The Division is
also ISO 14001 and ISO 50001 certified. The Division has ISO 17025 approved in-house
Laboratory for R&D activities in product development and testing.
Clientele includes various global Aerospace majors, Indian Space organizations, defense and
other Leading Engineering Companies.
MISSION
The mission of Foundry & Forge Division is to 1d0 deliver competitive products and
services that meet or exceed their customer’s expectations. They achieve their mission by:
•
Understanding customer’s need
•
Develop their human resources
•
Using systematic selection, develop technical support and surveillance of our suppliers
and sub-contractors
•
Improving regularly the facilities
•
Continuously improving manufacturing methods
•
Introducing product improvement based on customer feedback
There are different production shops in the division,
•
Powder Metallurgy shop
•
Ferrous Foundry,
•
Nonferrous foundry
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•
Pattern shop
•
Rubber shop
•
Ring rolling, magnesium foundry.
•
Precision foundry
•
General forge
•
Die shop
•
Machine shop
•
Precision forge
•
Shape memory
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Some of the other departments are,
•
CMPL (LAB)
•
Quality control and Development department
•
HR
•
Marketing & Store
CERTIFICATES
•
AS9100 D
•
NADCAP (Non-Destructive Testing)
•
NADCAP (Heat Treatment)
•
ISO14001 (Environment Management)
•
ISO50001 (Energy Management)
•
ISO 45001 (Occupation Health & Safety)
•
ISO 27001 (Information Security Management)
•
ISO/IEC 17025:2005 (NABL) Certifications in the following areas
•
Chemical Testing
•
Mechanical Testing
•
Non-Destructive Testing
•
Mechanical Calibration
•
Thermal Calibration
•
Approvals from various global and domestic customers
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WEEK 1
CHAPTER 3
POWDER METALLURGY SHOP
The Powder Metallurgy Shop of the division manufactures wide range of sintered friction and
anti-friction materials such as copper and iron-based brake pads, bimetallic anti friction Barings
and bushes for Aircraft. The facility has been approved by Indian Airworthiness Authorities for
design, Development, Manufacturing and Testing of military and civil Aircraft brake pads.
Infrastructure:
•
Twin roller pot mills and double cone blenders for powder mixing
•
100, 250, 500, 1500- & 3000-tons capacity hydraulic powder compacting presses
•
Hydrogen atmosphere pressure sintering Bell furnaces, Continuous pusher furnaces
•
Unique dynamometer testing facility for assessing performance characteristics of friction
materials and brake pads
•
Steps in Powder Metallurgy:
•
Basically, there are 4 different steps in powder metallurgy
•
Blending (mixing)
•
Solidification (compaction)
•
Sintering
•
Finishing
3.1.1
BLENDING
It is defined as the thorough intermingling or mixing of powders of the same nominal
composition. The implication with blending is that the constituents in the vessel are virtually
identical except for some minor physical characteristics. This is done using a double cone
mixer. Blending can take anywhere from 6hrs to 8hr. This yields a necessity to choose an
optimum blending time for any particular case of the mixture to provide a compromise between
the mixture homogeneity and mean fiber length.
COMPACTION
The friction material powder is pressed or compacted in 250 Ton press various parameters
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are considered while solidification such as load application tool used and type of machine
used.
SINTERING
It is a heat treatment applied to a powder compact in order to impart strength and integrity. The
temperature used for sintering is below the melting point of the major constituent of the Powder
Metallurgy material, during this operation density and bonding improved Hydrogen pusher
furnace for powder reduction & bulk sintering is used for loose sintering loading of charge
boats in pusher furnace Stacking of green friction compacts and backing frames for pressure
sintering Heating hood of furnace lifted after sintering
FINISHING
It is the process of removal of unwanted materials from the product. This is done by: Coining
or warpage removal and Dimension control machine.
Fig 3.1 Process Diagram- Powder Metallurgy Shop
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CHAPTER 4
FERROUS FOUNDRY
Ferrous foundry is specialized in the production of bimetallic break sector for MIG21 project
through CO2 mold process. The shop has a capacity for 200tons of metal melt capacity per
annum on per shift of operational basis.
Infrastructure:
• Automated Molding line with Core shooters
• Melting furnaces
• Low-Pressure Sand-Casting machine, Electrical and Gas Ford Rotary Degasser
• Vacuum heat treatment
• Surface treatments such as Chromating
• Radiography unit up to 300 KVA
• Unique Capabilities
• Complex shaped Aluminum alloy castings up to 400 kg weight
• Large magnesium alloy castings of size 1000 diameter * 600 mm height and 110 kgs
weight
• Castings with narrow ‘as cast’ oil passages of 4 to 10 mm diameter
Process Involved:
1. SAND PREPARATION
The first stage of the process was to mix the sand required to produce the casting. This started
by mixing dry silica sand along with tetra amine and dextrin used as a releasing and binding
agent respectively. These chemicals where then placed in a rotating mixer to forma uniform
sand mix. To this mix was added sodium silicate, sodium silicate has a unique binding quality
when exposed to carbon di oxide gas thus helping in production of a stronger mold. The mix
produced was then placed into a specially designed mold box with the pattern of the casting
placed in it; holes were then made through the sand (called vent holes). Through these holes
carbon di oxide gas was passed through these holes, as explained above the presence of
sodium silicate caused the sand to warp and become strong and stiff. The main form of pattern
used was a single pattern and there were two mold boxes one containing the shape required
and the other the means required for the flow of the liquid metal.
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2. CASTING PROCESS
The basic process of casting is to pour a molten metal into a mold of a certain shape and
dimension to produce the same shape of the mold. As seen above the moldrequired was set
and then we learned of the method used for producing the molten metal. Molten metal is
basically or commonly known as liquid metal, in the foundry we saw that the molten metal
was produced by the use of an induction furnace, the induction furnace works on the
principle of electrical induction through the use of coils, through which heat is produced
which then causes the metal to melt. To the furnace was an added raw piece of pig iron
which was melted and to which various chemicals were added to get the required amount
of carbon in the metal. When the metal had reached the required temperature for pouring
(found to be about 1540ºC) the mold boxes were laid out and were pre- baked using an
open flame passed into the boxes.
• To produce the bimetallic pads pre- manufactured steel plates were placed into the molds
over which the molten metal would be poured over.
• Once the metal and the molds were ready for pouring with the help of a ladle the metal
was poured into the mold boxes through the gating systems provided in the boxes. The metal
was then allowed to rest in an open environment and allowed to cool back to room temperature.
Once this was done the mold box was broken open and the solid metal that remained was
extracted. By the use of fettling tools, the excess sand and material on the cast was removed
and a rough cast plate was found, the plate was then sand blasted (the processof producing a
smooth surface by jetting sand at high velocities to impinge on the surface of the cast thus
producing a smooth finish), sand blasting helps in preventing the new cast from gathering rust
from the environment. The finished cast was then sent to the machine shop for further
processing.
• The Foundry & Forge Division has the infrastructure and expertise to manufacture
radiographic quality castings to international standards. This section offers Radiographic
quality Castings in a wide range of Aluminum and Magnesium Alloys to stringent
specifications of customers.
The main areas are:
• Aluminum alloy Sand and Gravity Die castings.
• Magnesium alloy Sand Castings.
• Investment castings in Aluminum Alloys, Steels and Vacuum Melted Nickel Alloys.
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CHAPTER 5
NON-FERROUS FOUNDRY
In F&F division Aluminum and Magnesium casted products are made and these come
under nonferrous foundry.
ALUMINIUM FOUNDRY
Aluminum foundry has facility to produce a wide range of high-quality sand casting and
gravity die casting for aeronautical applications and general engineering application Al
foundry caters mainly to other divisions of HAL particularly engines divisions. Its supplies
parts to external and exports customers.
Infrastructure:
• Full-fledged automated foundry with Automated Molding Line and core shooters.
• Melting facility up to 1.5 Ton.
• Low-pressure sand-casting machine.
• Sand reclamation System.
• Heat Treatment furnaces including Bottom Quench facility.
• Spectrovac facility for chemical analysis.
Capabilities:
• Capacity to manufacture casting to Grade- B and Grade-C as per E-155 requirement with
wall thickness of 2.5mm and narrow cast oil passages of 4- 10mm Diameter.
• Manufacturing capability to produce customized alloys in Al-Si-Mg, Al-Cu-Mg & Al- SiCu-Mg based alloys.
• Capability to cast Critical profiles: Valute and Aero foil.
Process Involved:
There are 3 sections in order to get the required casting.
Mold section: This section at the foundry produces sand molds in an automated machine
The process of mold making is described: first of all, the sand should be filtered properly and
is mixed well with a binder, accelerator and catalyst, and fed into binding machinethere
are 2 binding machines present in shop, they are 8-ton capacity and 25-ton capacity Wesman
binding machine. Then the mixed sand is poured into a mold box containing the pattern for
the casting and is compacted. This mold box is rotated in the vertical direction to separate
the pattern from the mold.
The other half of the mold is also made in the same fashion, and the operation repeats in a
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same way. The cores required are made by filling sand and binder into core boxes. These
cores, along with the chaplets, ceramic filters etc. are assembled on another conveyor belt,
to obtain molds which are ready for the liquid metal.
Melting section: In this section melting of the required alloys (Al) takes place which uses
Oil fired and gas fired furnaces. Aluminum tends to dissolve gases, so degasser is used to
minimize the dissolution of gases in the melt and maximize the removal of any such dissolved
gases. Air or nitrogen is used for purging the dissolved gases. Once the meltingis complete;
a sample of the melt is subjected to optical emission spectroscopy to ensurethe presence
of all required components in the right quantity in the alloy. Once this is done, the molten
metal is poured into the mold. Usually, copper powder is dusted on the top to ensure metal in
the risers stays in the liquid state for a longer duration.
Fettling section: The fettling section where removal of the excess metal in the casting is done.
Such as the risers, sprue and gating system etc. The section uses horizontal and vertical cutting
machines with bimetallic band saw blades with 4 to 6 teeth per inch. After cutting the excess
metal, the casting is subject to milling to remove out the cutting marks. The final cast is subject
to fluorescent dye penetrate test. For test the presence of any surfacedefects. And then it is
subject to radiography to detect bulk defects. Type of sand used: AFS 60(fine sand) is used
to make the mold. The sand needs to be preheated to remove any moisture content that might
be present.
MAGNESIUM FOUNDRY
Magnesium foundry is unique and the only largest magnesium foundry in country. It has
developed and manufactured complicated casting for aeronautical and aerospace application.
Its internal customers are helicopter division, engine division, aircraft division, and Lucknow
division Kanpur division etc. of HAL. The shop has a melting capacity to melt and cast 115Tons of Magnesium alloy per annum.
Infrastructure:
• Flux less melting facility to melt and cast up to 200 Kgs.
• 400 Kgs melting furnace with allied infrastructure like Sand Mullers (300Kgs), Sand
Mixers (50 Kgs) and Electric Core Ovens.
• Fluro- anodizing facility for cleaning of all passages.
Capabilities:
• Thin Walled, Intricate, large dia and large surface area Sand castings with narrow as cast
internal oil passages for Gear Boxes of Helicopters and other Aerospace applications.
• Castings produced in High strength Mg alloys such as MSRB, RZ-5, EQ- 21 andAZ91C.
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Difference between Aluminum and Magnesium casting
• The oxide film formed on aluminum surface makes it impermeable to further oxidation.
This is not the case with magnesium. Hence fluxes are used while melting magnesium to
prevent oxidation.
• The corresponding fluxes for commonly used alloys are given below:
1. HE flux is used for RZ5 (Alloy).
2. UE flux is used for GA9 (Alloy).
3. TE flux is used for MSRP (Alloy).
• Inhibitors like Potassium Chloroborate are used in magnesium casting to avoidburning.
These inhibitors are added during mixing and before binder addition.
• During pouring of metal sulfur dust is added to avoid burning.
Fig5.1Aluminium based Casted product
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Fig 5.2 Magnesium Alloy die casting Part
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WEEK 2
CHAPTER 6
PATTERN SHOP
Types of Pattern:
Single piece pattern:
It is simply the replica of the desired casting. It is slightly larger than the casting. This pattern
may be of wood, metal or plastic (hard plastic).
Match plate pattern, Cope & drag pattern, lagged-up pattern, Built up pattern, Multi- piece
pattern, Gated pattern, Sweep pattern, Skeleton pattern, Shell pattern and loose piece pattern,
Left and right hand pattern, Follow board pattern, Segmental patterns are some of the types
of patterns.
To compensate for any dimensional and structural changes which will happen during the
casting or patterning process, allowances are usually made in the pattern.
Allowances:
•
Contraction allowances / Shrinkage allowance:
The metal which undergo shrinkage during solidification and contract further on cooling to
room temperature. To compensate for this, the pattern made larger than the required
casting. This extra size is given on the pattern for metal shrinkage is called shrinkage
allowances.
•
Draft allowance:
When the pattern is to be removed from the sand mold, there is a possibility that any leading
edges may break off or get damaged in the process. To avoid this, a taper is provided on
the pattern so as to facilitate easy removal of the pattern from the mold, and hence reduce
damage to edges. The taper angle provided is called the Draft angle
•
Finishing or machining allowance:
The surface finish obtained in sand castings is generally poor (dimensionally inaccurate), and
hence in many cases, the cast product is subjected to machining processes like turning or
grinding in order to improve the surface finish. During machining processes, some metalis
removed from the piece. To compensate for this,a machining allowance (additional material)
should be given in the casting. The amount of finish allowance depends on the
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material of the casting, size of casting, volume of production, method of molding etc.
Pattern shop color identification for sand casting and core boxes used only in the
division:
RED: Casting surface
BLACK: Core print area
YELLOW: Runner bar, Riser, In-gates, down sprue Black back ground with yellow strips
chill location
Steps in pattern making:
• Prepare layout to full scale on AI sheets based on casting drawing
• Develop templates in AI sheets
• Cut wood, plane router and laminate for pattern and core box
• Rough mill the blocks
• Mill/turn the shapes
• Assemble the pieces in case pattern /core box are to be made in a number of details
• Finish the shapes by bench work
• Prepare the match plate
• Fix the match plate with pins
• Mark the match plate with pins
• Mark the match plates for pattern locations. Fix patterns
• Layout the gating system on a ply wood
• Cut wood, plane router and laminate for gating and risering
• Develop gating and rinsing as per layout
• Fix gating and risering system on match plate
• Mark identifications such as project and part number on match plate /follow board
• Arrange for mold and core and sort out mold /core assembly problem
• Release the pattern for proving trial
• Inspect the TP casing for dimension and report
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• Rework the pattern as per report
• Inspect the pattern for rework carried out
• Release the pattern DAR bath
• Rework the pattern for DAR snag
• Inspect the pattern /casting for DAR snag
• Release the pattern for production.
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CHAPTER 7
RUBBERSHOP
The rubber shop produces O-rings, gaskets, seal, shock mounts etc. are manufactured to
stringent aeronautical specification. Several high-performance elastomeric compounds
such as nitrile rubber, neoprene, silicone, fluorocarbons, Flurocarbon, Flurosilicone,
EPDM etc. have been developed.
Process Involved:
O-rings are manufactured as mentioned below:
 The die of the extruder is heated to 140 degrees before extruding
 Rubber is introduced and pressed with a pressure of 1500-2000psi for15 minat
17020 degrees
 After extruding we take the wire rubber to make‘O-rings
 This extruded rubber is placed in different dies to produce different types of
‘O-rings
 This extruded rubber is pressed at a pressure of 2000 psi
 The ‘O-rings are obtained in the cavity provided and the excess rubber which is
called flash is removed
 POSTCURING: Postcuring is doneto obtain required hardness.
The obtained ‘O’rings are heated to their respective curing temperatures for a given
time. This is called postcuring.
Two rolling millsat high temperature are used to produce sheets of thickness of
about 8mm. Pressure applied is about 2100psi and temperature is 180OC.Different
rubbers are used based on the application conditions i.e., silicone rubber is used for
low temperature application and Viton is used for high temperature applications.
Infrastructure:
 Hydraulic presses up to 150-ton capacity with automatic temperature and time
control
 Roll mixing mills
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 Extruder
 Hot air ovens
Unique Capabilities:
 Mouldedproductswithclosetolerancelimitsof±0.02to+0.1mmuptoasizeof200*2
00*200mm.
 Development of rubber compounds to any specifications and pre-determined
requirements.
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CHAPTER 8
RING ROLLING SHOP
The Ring Rolling facility has a state-of-the-art Ring Rolling mill incorporating the latest
technology including computerized control of operation and laser measuring device.
The Ring mill is also capable of manufacturing profiled rolled rings in variety of ferrous and
non-ferrous alloys.
The unit also has an expertise and technology for manufacture of rings in Maraging steel,
a strategic material used for defense and aerospace applications, with the close control of
hot working and heat treatment process parameters.
The ring rolling shop in HAL produces ring like structures for aircraft applications. Ring
rolling facility has a ring mill with latest technology.
The ring rolling mill capable of manufacture profiled rolled rings in a variety of ferrous and
nonferrous alloys. The benefits of profile rolled rings are reduced input material content,
desired grain flow along the rolled profile and improved metallurgical properties.
The unit also has the expertise and technology for the manufacture of rings in maraging steel,
a strategic material used for defense and aerospace applications such as:
•
Ti6Al4 alloy is mostly used in aerospace. This can easily forge.
•
Ti6Zr3 alloys are difficult to forge.
•
Maximum diameter of the ring produced is 3000mm.
Products:
•
Small rings used in aircraft engines.
•
Larger rings which are used as bearings in helicopter and in transmission parts, battle tanks,
and satellite launch vehicles.
•
Titanium, Nickel and Steel rings which are used in helicopters.
Infrastructure:
•
Fully computerized Ring Rolling mill 100/63 T radial/axial Force
• 3000T Hydraulic press
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• 1500T Upsetting press
•
•
800T and 500T capacity ring expansion
Battery of electrically heated low and high temperature furnaces with temperature
controllers and recorders
•
Bottom Drop Quench furnace for heat Treatment of Aluminium alloy rings up to 3.5mm.
Capabilities:
•
Rolled rings in all wrought alloys including super alloys
•
In-house facilities for pre and post-rolling operations including Heat treatment, ring
expansion/compression, Nondestructive and Destructive tests
•
Ring expansion or compression for relief of residual stress in Aluminum alloy rings
•
Rolling of rings with either or both internal/external profiles for critical applications of
aerospace, Defense and other Heavy engineering applications.
•
Special processes like etching for titanium-based alloys to international standard
Process involved:
•
Rod is heated in the high temperature furnace (900oC – 1100oC). Those are electrically
heated furnace (slowly it raises the temperature – limitation, hence LPG suits mostly).
•
Pressing is done by hydraulic press 1500 ton).
•
Piercing which is nothing but making hole in that circular object. Tool steel is used for
punching hole whose wear resistance is high.
•
These are again kept for heating in the furnace under proper soaking period uniform
distribution of the heat). Over soaking leads to grain growth.
•
After heating, they are hot rolled in the ring rolling mill.
Ring rolling mill consists of mandrel, main ring, centering roll, two axial rods.
•
Centering rod has sensors which gives feedback.
•
Axial rods control the thickness of the rod.
• The rod is compressed between the mandrel and main ring.
• The rod will expand more in radial direction.
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• During heated, there may be some bending hence they are pressed under hydraulic press.
• After rolling, they are heat treated to improve the properties and then machined.
• After this they are cooled, and then tested.
X ray testing (radiography): X rays are passed through the rod. These can detect
internal defects (cannot detect the surface cracks and also cracks at the joining).
Ultrasonic test: ultrasonic waves are passed through the rod which can detect sub
surface cracks.
Nondestructive test: this can give information about the surface cracks.
Fluorescent penetration test: this can detect the presence of non-magnetic impurities.
Casting
Bar
Blank Forging steps
Upsetting
Piercing
Ring
Rolled
Casting
Cast Blanket
Ring
d
Fig 8.1 Process Diagram
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Fig 8.2 Process Diagram – Ring Rolling Shop
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WEEK 3
CHAPTER 9
PRECISION FOUNDRY (INVESTMENT CASTING)
Precision foundry is engaged in development and manufacture of precision investment
casting for aeronautical applications. It carters mainly to other division of HAL
particularly Aero engine division, Helicopter division, aircraft division, Kanpur &
Lucknow division.
Why do we need investment casting?
• Intricate shape
• Close tolerances
• Small size
High strength alloys Patterns used for investment casting are injection molded of either
wax or plastic. Paraffin and microcrystalline waxes are the most common base material
for patterns.
Infrastructure:
• Wax pattern injection machine
• NADCAP approved Vacuum and controlled atmosphere HT Furnaces
• Wax pattern assembly facility
• Fast curing Ceramic shell Manufacturing facility
• De-waxing autoclave
• Vacuum induction melting for super alloys
• Aluminum oxide grit blasting
• Induction air melting furnaces of Capabilities from 25Kgs to 75Kgs
• Radiography using x-rays and other non-destructive tests
• Robotic shell maker
• In house testing facilities
Capabilities:
• Thin walled, intricate and near net shape casting for airframe, Avionics, and Aeroengine applications with close dimensional tolerances.
• Equi axed castings with high temperature properties
• Castings made of high strength aluminum castings alloys such as Al-Cu-Ag, HSLA steels,
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stainless steels, Co & Ni based superalloys and Hast alloys.
Process involved:
1) The wax is injection molded into a master die, made of Aluminum. It is injected in
such a manner as tocover the inner surface of the mold uniformly.
2) Multiple wax patterns are created and joined together by a wax gating system,
consisting of a runner and sprue, to form a ‘wax tree’. The wax patterns are then dressed
to make the wax look like the finished piece.
3) The wax tree is dipped into a slurry of fine refractory material (primary slurry), like
zircon sand. Any excess is drained off, to produce a uniform coating. The fine material
gives smooth surface finish and reproduces the fine details. Then it kept for drying for
4 to 5 hours.
4) After that, it is stuccoes with coarser sand. The coating is allowed to harden for 4
to 5 hours. The above steps are repeated to give the required thickness of coating. For
Aluminum alloys, 8 such coatings are required. For steels, 6 coatings are applied.
Binders, like colloidal silica, are used to hold the refractory material together.
5) The investment is then dried, which takes about 16 to 48 hours. It is then put into
an autoclave to melt and remove all the wax.
6) Secondary firing is done to remove any remaining wax and moisture. The investment
is then preheated. This is done to increase dimensional accuracy of thefinal casting.
7) The molten metal is produced by melting metal it in vacuum heating furnace or
resistance heating furnace. The liquid metal is sent for spectral analysis, to check the
composition.
8) It is then poured into the investment, which has been placed cup-upwards in a tub
filled with sand.
9) After solidification of metal, the shell is knocked out by means of vibrations.
10) Sprue is removed, and the final casting is subjected to sand blasting. The casting
is near net which means that it is very close to the final shape required of the product,
reducing the need for machining.
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Fig 9.1 Green wax used in the models of
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Fig 9.2 Cold Wax Investing
Lost Wax Investment casting Casting
Fig 9.3 SchematicdiagramofInvestmentCasting
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CHAPTER 10
GENERAL FORGE
The General Forge Shop is, perhaps the only one of its kind in India with the capability to
manufacture forgings of various specifications of shape, size weight and numbers. The shop
has, since the early sixties, manufactured forgings in a variety of alloys in many complex
configurations.
The general forge shop has the unique capability and experience to cater to a large range of
customer specification of shapes sizes, weights and numbers. The forging process is designed
with the help of simulation software which enables design of perform and optimization of the
process the shop has manufactured forging in a variety of alloys in many complex
configurations. The raw materials used here are Aluminium alloys, Magnesium alloys,
Titanium alloys and steel.
Infrastructure:
• 3000 T Hydraulic press with standalone Die heating furnace
• 3200 T and 1000 T Direct Drive Screw presses
• Series of friction screw presses with die heaters – 2000T, 500T, and 300T
• 1 tons gravity Drop hammer
• Series of Pneumatic hammers of 1500 kg, 1000kg, 500 kg and 150 kg capacities.
• 250T Horizontal Up setter
• 1.5T meter dia rotary hearth furnace
• 45T and 70T Trimming presses
• 10T Counter Blow hammer with a 500T Clipping Press
• Cutting machines
• Battery of electrical resistance pre-heating furnaces with temperature regulating devices
• Shot blasting machine
• Full-fledged
Heat
treatment
furnaces
for
hardening,
tempering,
solutioning,
ageing,normalizing, and annealing with temperature controllers and recorders
• Process and fettling shops for degreasing, etching, electro – polishing and size etching
operations
Unique Capabilities:
• Manufacturing forgings for airframe, landing gear, aero engine and industrial gas turbine
applications.
• Capable to manufacture aero engine critical parts such as compressor blades, hot end
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combustion chamber parts and turbine discs.
• CAD/CAM/CMM route of design, manufacture and inspection of precision aero foil
blades, components and tooling.
• Forgings in all ferrous alloys
• Open forgings, closed die forgings and Saddle forged rings
Process involved:
• Metal is heated in a furnace
• The metal is then but under compressive forces by a process known as banning. Pneumatic
hammers of 1500, 1000,500 and 10 kg are available. These are Open Die Power Forging
hammers and use pneumatics to drive the hammer. These are used for closed and open die
forging wherein the hammer strikes a work piece which is placed on a die of required shape
and rains blows on it create an impression of the die. For example, the BANNING 1000 kg
hammer gives 100 blows per minute and the BANNING 1500 kg hammer gives 85 blows per
minute to the work piece.
• It is then put in a high temperature furnace
• Soaking time is given for proper heat transfer across the entire material
• In case of die forging hot metal is put between male die and female die, then die puts
pressure and metal takes shape of the die as shown in figure
Fig 10.1Closed and Opened Die Forging
HEAT TREATMENT FACILITIES:
Various furnaces are available for use in the heat treatment section. Most of these are
NADCAP approved and assigned various classes, based on the temperature tolerance range.
The temperature tolerance range is the temperature above or below the operating temperature
of the furnace, which can be tolerated by the furnace.
Some of the furnaces:
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HAL Foundry and Forge Division
•
2022-23
GH-10 Furnace is a Class 4 and Class 5 furnace with an operating temperature of 6501180°C.It is used for the process of annealing
•
GH-4 Furnace is a Class 1 and Class 2 furnace, with lower operating temperature than
GH10 furnace. It is an air circulation type furnace, where a fan is used to circulate air
and uniformly distribute heat within the furnace. This furnace is used for tempering.
•
GH-5 Furnace is a Class 2 furnace with operating temperature of 150-680°C .It is a type D
instrument, which means that it consists of 1 Main Controller and 1 Recorder for the
furnace. This furnace is also used for tempering.
•
GH-7 Furnace is a Class 3 and Class 4 furnace and can be used for normalizing, tempering
and hardening.
•
GH-3 Furnace is a Class 1 and Class 2 furnace with rather low operating temperature of
100-350°C.
Fig 10.2 Heating Treatment
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CHAPTER 11
DIE SHOP
• In this shop the die required for the forge shop are manufactured.
• The shape of die required is obtained from the development department. The dies are
manufactured by manually controlled cutting machines or by CNC. There are 2 types of
die shapes can be performed:
1)
Simple shape
2)
Complex shape
• Simple shapes are performed by conventional machining and Complex shapes are
performing through CNC machine.
• This shop has a VMC i.e. vertical milling center.
• The major difference between the precision forge and general forge is the tolerance and
the die.
• In precision forge we use a die with a wedge of angle 5 degrees.
• There are two routes for die making i.e. EDM route and other is CNC.
• EDM is preferred for simple shapes.
• The coolant used is mixture of oil and water as it acts as lubricant and helps in
dissipating heat generated due to friction.
• The dies are checked by using plaster of Paris as the molten metal and checked for cavity
formation.
• Tool steel of Rockwell C hardness 38-42 is the material for Al products and tool steel of
Rockwell C hardness of 48-52 for Ti and steel.
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WEEK 4
CHAPTER 12
MACHINE SHOP
Many components need to be finished and brought to appropriate dimensions after
casting, forging and heat treatment operations, as specified in route card given by the
development department. This is accomplished by machining the components on lathe or
milling centers.
HAL F&F division has its very own machine shop for such operations. Castings produced
are generally rough and must be finished on lathe or milling centers. The machine shop
consists of various lathe and milling centers ranging from vertical lathe to horizontal lathe
and vertical milling machines are also prevalent in the machine shop.
Difference between vertical and horizontal lathe is that vertical lathes have better
productivity and reduced cycle times than their horizontal counterparts. Vertical lathes
also help by not occupying large spaces.
Presence of vertical lathe helps the division to machine Nickel alloys, Titanium alloys,
variety of steels etc. at a reduced cycle time.
Machine shop is a supporting shop catering to the machining requirements of ring rolling,
general forge and precision forge and also for precision castings as described below:
• Machining of rings of minimum inner diameter 350mm and maximum outer diameter
1200mm in alloys of steel, nickel, aluminum and titanium.
• Machining of blade forgings as per work instruction.
• Machining of precision castings of steel, nickel, titanium and aluminum alloys
weighing from 5 grams to 6kgs.
• Machining of the test specimen before the production.
Machining of forging of steel, aluminum, titanium and nickel are described below:
Steel alloy: weighing from 0.25 kg to 60kg.
Aluminum alloy: weighing from 0.1kg to 25kg.
Titanium and Nickel alloys: weighing about 25kg.
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CHAPTER 13
PRECISION FORGE
As the name suggests, precision forge is done in order to minimize the machining after the
forging operation. Engine blades are mostly manufactured here. These are critical
components hence the process involves a lot of tests for defects etc. In this shop Titanium
and Aluminum engine blades of different sizes and also rotor blades of different sizes are
produced.
Description of the shop:
 The products are made from steels, titanium alloys, nickel base alloys and aluminum
alloys.
 Precision shop manufactures parts required for aircrafts such as rotor blades, stator blades
etc., of size varying from moderate to small which are near net forged so as to reduce the
extent of post machining.
 The forging temperature range for different alloys are givenbelow,
i.
Steels–1050oC-1150oC
ii.
Titanium alloys–940oC–980oC
iii.
Aluminum alloys-400oC-500oC
 The raw materials for this are either small billets or pre-forged materials which are
forged at high temperatures.
The forging is done along the grain flow direction. The parts are then sent
tofettlingsectionwheretheexcessortheunwantedpartsareremovedandsurfacefinishingis done. Hotblastisdoneto
remove scales formed.
 Thentheproductsaresenttofinalinspectionunittocheckwhethersurfaceandinternaldefe
cts are present and then they are passed for the service.
 Different processes to detect defects are done.
 Some of them are listed below:
 The products are degreased i.e., vapor degreasing or alkaline degreasing and
The netching and electro polishing is done.
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Infrastructure:
 Friction screw presses-capacities of 2000 tones,500 tone sand 300 tonnes
 3200Tand1000-tonnedirectdrivescrewpresses.
 A250-tonnehorizontalupsetter
 Abrasive blasting equipment
 Vibratory finishing mills
 Process shop for degreasing, etching, electro polishing and size-etching operations
 Fluorescent penetrant inspection unit
 Double-ended polishing lathes
 Dedicated inspection facility including CMM for precision forged blades
Unique Capabilities
 Complex precision forged products including aerofoil shapes in all wrought alloys and
precision blades from component drawing using CAD/CAM/CMM route of manufacture
 Custom built equipment for forging, processing and inspection of precision forgings
especially compressor and turbine blades
 Abrasive blasting and vibratory finishing equipment
 Optical projectors and multi-gauging equipment backed by checking fixtures, gauges
and other inspection aids
 Range of screw presses to undertake manufacture of a wide range of precision forged
products
Process involved:
Aluminum alloys (400-500 °C) are made by the following procedure,
 The raw materials for this are either small billets or pre-forged materials which are
forged at high temperatures.
 The forging is done along the grain flow direction. The parts are then sent to fettling
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section where the excess or the unwanted parts are removed, and surface finishing is
done. Hot blasties done to remove scales formed.
 Then the products are sent to final inspection unit to check whether surface and internal
defects are present and then they are passed for the service. • Different processes to detect
defects are done.
 The products are degreased i.e. vapor degreasing or alkaline degreasing and then etching
and electro polishing is done.
Fig13.1 Aero engine Airfoil
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CHAPTER 14
SHAPE MEMORY ALLOY (SMA)
Foundry and forge division has set up facilities for the manufacturing of shape memory alloys
(SMA) currently Ni-Ti-Fe alloy heat shrinkable sleeves for aircraft
application being
manufactured.
SMAs have the ability to remember the shape given during original thermo mechanical
processing allowing the material to revert to that original shape when subjected to heat.The
division has the capability to manufacture SMAs based on the customer’s specifications such
as chemical composition and transformation temperature.
Nitinol (alloy of nickel and titanium mixed in almost equal proportion) shows shapememory
effect. Shape memory alloys have the unique property of remembering their shape. Once
deformed, they revert to their original shape after crossing a certain transformation
temperature. The SMA shop at this division produces ferrule rings whichare used to clamp
polyether ketone tubes into aluminum tubing which carry fuel. Ferrule rings are made up of
Ni-Ti based alloy.
Infrastructure:
 Vacuum Induction melting furnace (VIM) - 50kgs capacity. The crucible used in here is
coated with yttrium oxide paint to avoid the reaction between nickel and graphite crucible.
Vacuum pressure of 0.005 Pa is be used.
 Vacuum arc re-melting (VAR)- up to 150mm diameter
 DSC- differential scanning calorimeter
 SEM- scanning electron microscope
 Universal testing machine for testing strength
 Rapid prototyping technology – It is like 3d printing of the sand molding. The computercontrolled sand mold is produced by pouring sand layer by layer and using binder where
required. In one pass the machine pours sand and in the nextpass it pours binder. The binder
holds the sand particles together and the loose sand is then removed by suction to get
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required shape. Sand layer of thickness 0.28mm is produced for every pass and the binder
used is fluron. The molds produced are for the products as follows volute casing (Al alloy
/A356), main casing (Mg alloy), filter housing (Mg alloy), free wheel housing.
 Sand storing silos of capacity 1200kg
 Rolling mills.
 CMM – Coordinate Measuring Machine

Fluorescent penetrant Inspection

Magnetic particle Inspection

Digital radiography

Ultrasonic testing

Hot Rolling Mill
Capability:

Production of SMA ingots.

Refining using vacuum arc remelting (VAR)

Forging of ingots.

Characterization using differential scanning calorimeter.
Process involved:

Ni-Tiof equal proportion are melted in vacuum induction furnace.

These are then refined in vacuum arc remelting to get pure SMA.

It is then tested in differential scanning calorimeter to monitor its transformation
temperature. Fluorescent penetrant Inspection

Magnetic particle Inspection

Digital radiography

Ultrasonic testing

Hot Rolling Mill
Capability:

Production of SMA ingots.

Refining using vacuum arc remelting (VAR)
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HAL Foundry and Forge Division

Forging of ingots.

Characterization using differential scanning calorimeter.
2022-23
Process involved:
 Ni-Ti of equal proportion are melted in vacuum induction furnace.
 These are then refined in vacuum arc re melting to get pure SMA.
 It is then tested in differential scanning calorimeter to monitor its transformation
temperature.
 This pure material is subjected to hot rolling, forging followed by heat treatment and
machining.
 Ferrules used for LCA have transformation temperature of -55 °C.
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CHAPTER 15
DEVELOPMENT DEPARTMENT
A company's research and development department play an integral role in the life cycle of
a product. Functional interface between the customer and manufacturing departments,
rendering technical support right from feasibility study to supply of first off parts to
customers. While the department usually is separate from sales, production and other
divisions, the functions of these areas are related and often require collaboration. This shop
is the brain of the division which gives the route card or process card which tells the way
in which a given product is produced. i.e., The different process through different shops it
needs to go.
Capabilities:
• CAD/CAM for design of dies and engine blade forgings.
• 2dimensional draft, 3dimensional modelling and CNC machine tools program design.
• Computer simulation route used for designing gating, riser and feeding system for castings.
New Product Research:
Before a new product is developed development, department conducts a thorough study to
support the project. The research phase includes determining product specifications,
production costs and a production timeline. The research also is likely to include an
evaluation of the need for the product before the design begins to ensure it is a functional
product that customers want to use.
New Product Development:
The research paves the way for the development phase. This is the time when the new product
is developed based on the requirements and ideas created during the research phase. The
developed product must meet the product guidelines and any regulatory specifications.
Existing Product Updates:
Existing products of the company also fall under the scope of development. The department
regularly evaluates the products offered by the company to ensure they are still functional.
Potential changes or upgrades are considered. In some cases, the development department
is asked to resolve a problem with an existing product that malfunctions or to find a new
solution if the manufacturing process must change.
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Innovation:
The research and development team aid the company in staying competitive with others in
the industry. The department can research and analyze the products other businesses are
creating, as well as the new trends within the industry. This research aids the department in
developing and updating the products created by the company. The team helps direct the
future of the company based on the information it provides and products it creates.
Objectives:
 Design and develop components manufactured in Foundry and Forge.
 Starting fundamental operations.
 Responsibilities:
 Feasibility study.
 Cost estimation.
 Constructive review. Develop a product drawing.
 Test Schedule – Testing requirements approved by customer.
 CAD/CAM, 3D modelling, simulation packages for gating system in casting and die
design.
 Conducting trials.
Customer
3DModelling
Simulation
RPT/Tooling
Manufacturing
Fig 15.1 Typical Process flow
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WEEK 5
CHAPTER 16
QUALITY CONTROL DEPARTMENT, MARKETING
DEPARTMENT
The Quality Control Department of the Foundry and Forge division operates on two levels.
At the shop level, engineering control is practiced while Quality control is adapted for the
finished product. Every department has quality control section and personnel. The QCD
interacts with these sections at the shop level regarding quality management systems,
approvals and customer complaints. These customers are either internal or external. The
external customers include Rolls Royce, Jaguar and Honeywell. The products manufactured
by the Foundry and Forge division for these customers include variouscastings, forgings such
as Aero-engine blades, rolled rings, metallo-ceramic and organic brake pads, bimetallic
sectors, rubber components and shape memory alloy ferrules.
The Quality Control Department abides by 3 Quality objectives:
•
To understand and meet customer needs.
•
To monitor process effectiveness continuously.
•
To reduce process and product non-conformances through a system of continuous review
and improvement.
The Quality Control Department conduct internal audits once in every 3 months to suggest
changes and corrections so that the manufacturing standards correspond to customer
requirements. These audits involve periodic analysis and calibration of furnaces,
thermocouples and other important equipment following the standard Quality Analysis
Procedure. The audits ensure that the manufacturing process proceeds as per the customer
requirement and the AS 9100 ISO standards.
These standards include:
•
ISO 9000: 2005 – Quality management system-Fundamentals and vocabulary
•
ISO 9001: 2008 – Quality management system-Requirement
•
AS 9102 – First article inspection
•
AS 10007 – Guidance on configuration management
•
AS 9100 Revision C – Aerospace standards
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These standards are required for special processes in the Foundry and Forge division such
as Non-destructive testing (NDT-004,006,015), Heat treatment (HPS-905,407) and
Laboratory testing (chemical, mechanical, and metallurgical).
Each section of the Foundry and Forge division has its own non-destructive testing personnel
who perform a routine battery of tests on the finished parts:
•
Dye penetrant test
•
Magnetic particle testing
•
Ultrasound testing
•
Eddy current testing
•
Radiography
Dye penetrate testing:
The part is cleaned and a uniform layer of the penetrant dye is applied on the surface. After
a certain drain time, the excess penetrant is drained off and a developer is applied to draw
the penetrant out of the flaws and cracks. The part is now viewed using a photo fluorometer
which emits ultraviolet light under which the fluorescent penetrant glows, revealing the
surface defects, if any.
Radiography:
Every section is equipped with a radiography room lined with lead. Two standard X-ray
machines of 160 kV and 250 kV are used to capture images of the finished part at different
angles and different exposures. The development of the exposed film is automated. The
images are usually 12” X 15” or 14” X 17”. Image Quality Indicators (IQI) are used in the
form of small wires of varying thickness to gauge the resolution of the images. A
densitometer is used to differentiate between the dark spots thus revealing the internal
flaws in the product. Rejected castings are thus either reinforced or discarded.
Here we basically check the quality of the product (can be final product o r in process
product) from that particular shop.
Eddy current testing:
Eddy currents are set up in the product with the help of a magnetic field induced by a current
carrying coil. The variation in the phase and direction of the current are altered by means of
a receiver coil. This set up detects changes in the magnetic permeability of the specimen
which is useful in pointing out internal flaws and defects as they cause the Eddy current to
fluctuate.
Ultrasound testing:
Short Ultrasonic pulse waves with frequencies from 15 to 50 Hz are directed at the
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specimen from an electronic transducer. The reflected pulses are sensed by a receiving
transducer which converts the signal into useful data based on the distance travelled by the
pulse. The signals are transmitted to the specimen through a couplant or medium. The data
from the transducer is displayed on a monitor in the form of an image where the flaws can
easily be recognized.
Magnetic particle testing: In MPT, magnetic powder (Magnaflux) is applied on the
specimen or welded area and then a current passed through it. The flow of the current is
impeded by flaws in the material which results in the formation of opposite poles and leakage
of flux at the site of the flaw. The magnetic particles align themselves along the direction of
these poles thereby revealing the location of the flaw.
The procedure has specific documentation requirements:
1. Quality manual QM-01 (with policy statement and objectives statement)
2. Quality assurance procedures
3. Quality control work instructions
4. Departure manuals
If the results of the audit uncover a non-conforming part which does not meet the required
standards, the customer is notified within the next 24 hours. This is followed by further
analysis of data and preventive action.
MARKETING DEPARTMENT
The marketing department of a company promotes the company and drives sales of its
products or services. It provides the necessary research to identify the company’s targeted
customers and other audiences. HAL foundry & forge division also has a marketing
department. Around 50% of the division’s income comes from offering services to nongovernmental companies be it national or international. International aerospace companies
like Boeing, Volvo, Airbus, Rolls Royce etc. While national customers including
governmental organizations include BHEL, BMEL, IPL, TATA POWER, INDIAN AIR
FORCE (IAF) etc.
Process involved:
• Request For proposal (RFP) is filed.
• Evaluation at marketing department.
• Development department & engineering department.
• Quotation is submitted to customer.
• Tender opening (if quality & delivery time are not out of bounds, then supplier selling
at lowest price is given the order).
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• Negotiations (commercial or technical) take place.
• Purchase order is released.
• Contract review is made.
• After supplies, payments are collected.
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CHAPTER 17
STORES
This comes under integrated material management (IMM) There are 3 stores are
present in HAL F&F division
•
Goods inward store
•
Holding store
•
Salvage store
Goods inward store:
Purpose: To defines a procedure for receipt and issue of material to holding store.
Activity description:
•
Material received at receiving and Quantity received is checked against the DC
•
Waybill is prepared.
•
RR No. is assigned, and RR is generated.
•
Monitor color coding of raw material.
•
Received quantity is moved to GI store and sent to inspection along with other
documents
•
Materials is inspected, and test certificates are verified
•
Charges approved for the accepted quantity
Holding stores:
Purpose: To define a procedure for storage and issue of materials
Activity Description:
• Receipt and storage of incoming materials from GI stores
• Receipt of items sent from GI stores after charges approval
• Verification of parts numbers, description project class, RC codes UOM of items and
segregates the items according to storage condition and location
• Receive of materials and updation of records /stock in IFS and finalize
• Identify/store the items in respective location such that issue can be made on first in
first out basis
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• Materials are stored as per the goods storage practices /methods &preservations for
various types of materials as mentioned in the stores manual
• Issue of materials
• Receive MR / pick list &check the correctness of the contant of MR
• Check the availability of item
• Collect the item from Bin /storage location
• Enter the details like quantity issued serial number etc. in the MR
Salvage stores:
Purpose: To define a procedure for management of scrap /surpluses
Functions: Salvage stores is mainly responsible for following functions
•
Receipt of scrap, surpluses etc.
•
Proper storage and preservation of scrap/surpluses
•
Handling of surpluses/salvage store
•
Reclamation of items &re issue
•
Effort to sell surpluses item before disposal
Reasons for scrap development:
Scrap/surplus normally occurs due to following reasons:
•
Damage of items beyond economical repair
•
Expired life items whose life cannot be extended
•
Items becoming absolute due to technical changes, phasing out new issue, modifying items
etc.
•
Item completing normal operation life.
•
Corrosion and deterioration beyond economical use.
•
Rejection of items at receipt.
•
Small cut items and other scraps produced during manufacturing.
•
Tool rejection review committee declared tools & gauges.
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CHAPTER 18
CMPL (CENTRAL MATERIALPROCESSINGLAB)
CMPL is divided into the following sections,
•
Chemical inorganic section
•
Chemical organic section
•
Calibration section
•
NDT section
•
Metallurgy section
•
Mechanical testing section and workshop
•
Learning center and documentation unit
Testing and quality
Chemical, metallurgical and mechanical testing of
control
Raw materials, in process and finished Products.
Calibration
Calibration of measuring instruments and
pyrometers
Technical
Service and process failure investigation
investigation
NDT (Non-
Training and certification
Destructive Test)
NDT consultancy techniques and documentation
Researchand
Materials development, design anddatageneration
development
Development of special processes and products
Learning center
Training, documentation and library service.
Table18.1 Functions of central materials and processes laboratory
Chemical section:
Facilities
•
Atomic absorption spectrometer GBC
•
Direct reading optical emission
•
Spectrometer BAIRD 1000-DVA
•
UV-Visible spectrophotometer systronics
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Hydrogen determinator LECO RH 404\
•
Carbon/Sulphur determinator LECO CS 200
•
Saltspraytestcabinet-ASCOH455t
•
Taber abrasive apparatus
•
Karl-Fischer titrator – Metrom
•
Conductivity & PH meter-Metrom
•
Flame photometer
•
Breakdown voltage tester Zeal ZSHV SAV
•
Coating thickness tester (Dual scope MP40)
•
PTC digital durometer
•
Saybolts universal seconds viscometer
•
Brookefieldsynchro electric viscometer
•
Micro hardness tester
•
Microwave accelerated reaction system MARS5
Service:
•
Analysis of chemical compound by instrument/wet analysis
•
Analysis of plating & surface treatment solution for process consistency
•
Salt spray test – accelerated corrosion resistance test
•
Chemical analysis support in characterization of metalloceramic and phenolic composite
friction materials for brake pads
•
Testing of adhesives, sealants, oils, fuels, paints, rubber, plastics.
Calibration section:
Service offered
•
Calibration of all type of thermocouples 15C-1100C)
•
Onsite calibration/temperatures uniformity survey of furnaces
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Calibration of weighing balances
•
Calibration of cable tensiometers, mechanical force gauge, Vickers hardness testing
machine, Rockwell hardness testing machine, Brinell hardness testing machine.
Facilities:
•
Tubular thermocouple calibrating furnace 0c-1200C)
•
Isotech and fluke portable thermocouple calibrating furnaces (150C-1000C)
•
Fluke 525/A temperatures/pressure calibrator
•
Isotech quick calculation low temperature thermocouple calibrating furnaces (15C140C)
•
Fluke R type reference thermocouple with built in junction
•
Microtech torque wrench tester 0.55kgfm 4
Non-Destructive Test Section:
Facilities
•
X ray equipment -225kV constant potential
•
Ultrasonic flow detector microprocessor based)
•
Eddy current flow detector
•
Eddy current equipment for conductivity checking with NIST traceable standards
•
Photo fluorimeter for checking the brightness of fluorescent penetrant
•
Magnetic yoke for magnetic particle inspection.
Services
•
Radiographic inspection of casting, welding’s, assembled components
•
Electrical conductivity check by eddy current method
•
Ultrasonic and eddy current inspection
•
Magnetic particle inspection
•
Penetrant test.
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Metallurgical section:
Facilities
•
Nikon Inverted), Levitz upright) optical microscope
•
Automatic image analyzer
•
Stereo binoculars microscope
•
SEM with EDAX
•
Ferrite meter
•
Automatic sample polisher
•
Portable hardness tester
•
Beula micro hardness tester
•
Indented universal hardness tester
Service
•
Macro structural analysis & macro etching of ferrous and non-ferrous materials
•
Micro structural analysis of metals & alloys by metallographic techniques
•
Estimation of grain size by microscopic method
•
Determination of non-metallic inclusion rating, graphite flake size, type and distribution in
cast iron
•
Pre examination of metallochromic brake pads
•
Depth of decarburization of steels
•
Micro and macro hardness of metals and alloys
•
Case depth measurement in low carbon steel by micro scoping and hardness test
•
Measurement of cavities and plating thickness by microscopy
•
Investigation of accident or incident of aircraft & general engineering components.
Mechanical testing section:
Some of the facilities
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Servo hydraulic UTM-100kN Dartec
•
Servo hydraulic UTM-100kN Zwick
•
UTM -25kN TIRA
•
UTM-25kN INSTRON
•
Avery tensile testing machine-450Kn
•
Creep and stress rupture test machine- SATEC, INSTRON & GLOHEAT
•
Charpy & Izod impact testing –FTM, Avery& FIE make
•
Rotating bending fatigue test machine (RT)
•
Stress corrosion cracking test machine –Alternate and constant immersion
•
Elevated temperature rotating beam fatigue testing machine.
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Research and development:
•
CMPL provides technical data, testing and analytical service for:
•
Metallic, Nonmetallic and engineering materials
•
Development and manufacture of metallochromic and phenolic composite
friction materials for high energy brakes.
•
Development and manufacture of large and complex casting of Al, Mg, Cu base
alloy, cast iron, special high-performance metals and alloys.
•
Development of aero engine compressor blades and other general and precision
forgings in high strength Al alloy, Steels, Ti, Ni based super alloy.
•
Identify the root cause of failures and recommend remedial measures to prevent
recurrence of such failures.
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CHAPTER 19
CONCLUSION
1)
This division supplies the products to the various other divisions of HAL
manufacturing Aircraft, aero engines besides the space, defense, railways and other heavy
engineering industries with an aim to become a significant global player in the aerospace
industry.
2)
Having well-equipped facilities, it provides competitive products and services with
regular quality check at each phase of manufacturing without compromising the customers
expectation.
3)
The aim of HAL is to achieve self-reliance in design, development, manufacture,
upgrade and maintenance of aerospace equipment diversifying into related areas and
managing the business in a climate of growing professional competence to achieve world
class performance standards for global competitiveness and growth in exports.
4)
More importance is given to the quality of products as well as meeting the demands
with minimal loss of resources.
5)
1The crux of aerospace manufacturing, from what we have learnt at HAL
Bangalore Foundry and forge division is traceability of component and zero compromise on
quality of manufactured products.
6)
Division manufactures castings, forgings, rolled rings, brake pads, shape memory
alloys and rubber products for applications in the aeronautics, defense, locomotive, earth
mover and other industries.
7)
The products manufactured here are used in defense and called as backbone of
defense.
8)
From past 7 years HAL is helping defense for manufacturing, overhauling and
Bend is controlled by the height from which the rammer falls which is often adjusted
by the operator with help of switches and a foot pedal that controls the motion and velocity
of the rammer. When the pedal is pressed the rammer is disengaged from the brake causing
it to drop.
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