The Design and Engineering Department at HAL, Nasik was established in the year 1964. Since then it grew in strength, capabilities, expertise, infrastructure, skills, experience and facilities to support the license manufacture, overhaul of Russian series aircraft variants MiG-21, MiG-27, and SU-30 MKI aircraft in terms of modifications, repair, rectification and airworthiness certification.
Significant contribution in

• Product Improvement       
• Aircraft Upgrade
• Life Extension Studies
• System and Stores Integration
• Indigenisation
• Design Engineering
• Simulation Analysis and Testing
• Provides support to Indian Air Force and Indian Navy.
• Full-fledged   R&D centre   since   1998 as "Aircraft Upgrade Research & Design Centre (AURDC)" part of HAL Design Complex with head office in Bangalore.

AURDC has been recognised as:

• In-house R&D Centre by Department of Science and Technology (DST), Government of India.
• Approved   by 'Centre For Military Airworthiness   & Certification (CEMILAC), Bangalore.
• NABL Accrediated Labs
• AS 9100D Certified

Accolades/ Laurels
AURDC has received more than 50 Prestigious awards for its contribution in design, innovation and providing solutions for country’s defence forces:

• Raksha Mantri’s Award for Excellence
• “Dr. Biren Roy Trust Award” by AeSI
• “Golden Peacock Innovative Product/Service Award”
• SODET Awards
• National Technology Innovation Award

Patents/ Technical Papers
Over the years AURDC has transformed into a full-fledged R&D Centre of HAL with
 
Patents
108 Patents (Filed)
31 (IPR’s) Granted
 
Technical Papers
More than 105 technical papers are published as on date by AURDC in journals, national and international conferences

Tie – Ups
AURDC has close association with academic and R&D Institutions (IIT, Mumbai, ICT, Mumbai
CSIR-CSIO, Chandigarh)

 

As the R&D house of HAL specialised in Russian fleet, AURDC has full integration and Testing capability. Working closely with the IAF, we have learned its operational requirements and have developed diversified capabilities to best support our customer's specific needs.

AURDC's vast experience in providing design solutions to military aircraft serves as a wide base for providing customised system Integration solutions, upgrade solutions which best suits the customer requirements.

• Successful and timely execution of avionics upgrade of 40 Russian origin MiG-27 ML fighter-bomber aircraft indigenously.
• Operational and combat enhancement of Su-30MKI, MiG-21 variants and non-HAL aircraft like An-32, Tu-142 etc. by integrating state-of-art weapons and systems.
• Equipped for taking up major aircraft upgrades.

We offer upgrading of fighter and rotary wing aircraft in the following main areas:

• Advanced Avionics and Systems
• Modern Pilot Friendly Cockpit
• Wide range of Weapons and Stores 
• Structural and Maintenance Improvements
• Electronic Warfare Suite
• ECS System improvements
• Life Extension

AURDC provides Solution for Aircraft Modernisation and Mid Life Upgrade
 

• AURDC has a core competency in:
  • Life Extension of Russian aircraft
  • Role Equipments
  • Engines and its Rotables
• Developed indigenous technology for Life Extension
• The expertise used in extending life of non-HAL produced Russian origin aircraft like MiG-23, Tu-142, An-32,   MiG-29 and MiG-25 aircraft.
• Centre of excellence for Life Extension Studies for Russian aircraft using various facilities established in house.

Time Between Overhaul (TBO) Extended

Su-30MKI  and its Rotables:            Increased by 40 %
MiG-21 Variants and its Rotables:   Increased by 20 %
 

Total Technical Life (TTL) Extended

• MiG-21 variants (Main and Nose landing gear): Increased by 50 %
• MiG-27(Main and Nose landing gear):  Increased by 70 %

 Airframe Life

MiG-21 BIS (T-75) :                  Increased by 40%
MiG-21 E7FL (T-77):                Increased by 10%
MiG-21 M (T-96):                      Increased by 13%  

Total Calendar Life (TCL) Extended

• MiG-21 variants, MiG-27 and Su-30MKI mechanical rotables to unlimited
• MiG-21 variants and MiG-27 electrical rotables by 50%
• MiG-21 T-69 trainer aircraft by 13 %

We Provide Solution for evolving life extension methodology for aircraft and
rotables to our customers.

SYSTEMS & STORES INTEGRATION

AURDC with its experience of Integrating 600+ systems on MiG-21, MiG-27, SU-30 MKI, TU-142, MiG-23UB and AN-32 platforms offers end-to-end solution for integrating new systems on fighter aircraft and Helicopters.

AURDC also is a centre of excellence in Stores Integration of different type and class on MiG series and SU-30 MKI aircraft.

We Offer Innovative Solution for Fighter, Civil and Rotary Aircraft towards:

• System Integration (Avionics, Electrical and Mechanical Systems)
• System Design of ECS and Fuel systems
• CFD Analysis for System Integration
• Carriage and Separation Analysis
• Store Integration
• Flight Test Instrumentation
• Structural and Maintenance Improvements
• Design Improvements

More than 20 Stores have been successfully integrated till date.
 

AURDC over the decades towards company's self-reliance endeavor in aircraft manufacturing and overhaul programs have carried out indegenisation of various Mechanical spares, Electrical Rotables, LRUs, Non metallic material, GHE and GSEs, Consumables and Metallic materials for aircraft like MiG-21 series, MiG-27, MiG-23, MiG-25, MiG-29, Su-30 MKI and Su-30 MKI ROH. As on date more than 69,000 items have been indigenised.

The capability gained is also utilized for indigenisation of items for Transport aircraft likeAN-32 and IL-76 and Helicopters like Mi-9 and Mi-17. More than hundred Private Business Partners have been developed for indigenising different variety of material and rotables for aerospace applications.

AURDC also has capability for Design and Development of Ground Handling Equipment’s (GHE’s) and Ground Support Equipment’s (GSE’s). More than 85 GHE/GSE have been designed and developed by AURDC

Services Offered
AURDC  has  tools  and  expertise  to  perform various analyses for aircraft and Systems:

• Linear I Non-Linear
• Static
• Stress and Fatigue
• Buckling
• Modal
• Random Vibration
• Flutter
• Bird Impact
• Weight and CG
• Heat Load Analysis
• Electrical Load Analysis
• Software data Analysis
• Systems
• Environmental Control System
• Hydraulic & Fuel System

Testing
 AURDC has NABL approved facility and expertise for performing following Testing:

• Mechanical
• Chemical
• Non-Metallic
• Non Destructive

Additionally following Testing facilities also exist at AURDC:

• Static Testing
• Resource Testing
• Metallurgical
• Environmental
• Material
• Environmental Control System

It also has Manufacturing facility for Rubber and Adhesive used in aircraft application.
 

AURDC also has expertise in:

• Design of Fuel Drop Tanks for fighter aircraft
• Design of Hydraulic Valves and Filters for Fighter aircraft.
• Simulation of Environmental Control System of fighter aircraft and UAVs.
• Fight Data Analysis.
• Airworthiness Certification of systems of Fighter aircraft.
• Defect, Accident, Incident, Technical/ Safety cell Investigation and Analysis.
• Engineering Solutions and Product Support
• Evolving Repair Schemes and Rectifications

 Training
AURDC has a full-fledged training and e-Learning
Centre and Offers training to pilots, Operators and Maintenance personnel on Russian aircraft:

• Operational
• Maintenance & Repair of Russian origin aircraft
• Air Crew
• Other service Personnel

Aircraft Publications
AURDC is also a publication centre for aircraft documents for MiG-21, MiG-27 and Su-30 MKI
aircraft.
AURDC also produces aircraft publications including

• Aircraft Flight Manuals
• Aircraft Maintenance Manuals
• Illustrated Part Catalogue
• Aircraft Test Schedules
• Flight Test Documentation etc.

AURDC provides Technical Consultancy and Training to IAF, Indian Navy, and Coast Guard on Russian Fleet of aircraft.
AURDC has also provided training to   Maintenance personnel of Royal Malaysian Air Force on Operation of SU-30 MKM aircraft
We Provide State of the Art Trainee and Aircraft documentation Solutions to our customers.
 

Since its inception, AURDC has equipped itself with various Laboratories with work stations having high end software:

• CAD/CAE
• Central Lab
• Computational Fluid Dynamics (CFD)
• Software Development & Analysis
• System and Stores Integration
• Static and Resource Testing
• Flight Analysis

 
AURDC has over the period of time established various labs including Static Testing and Resource Testing facility to carryout integrity test of GHE, endurance testing of aircraft components, structures.

 World Class Testing Facilities

• Thermo bar Chambers
• Accelerations
• Microprocessors Controlled ovens
• Shaker Vibration Test setup upto 1300 Kgf
• Universal Tensile Testing Machine
• Fourier Transform Infrared Spectrometer
• Karl Fischer Moisture Analyser( PPM level )
• X-ray machines for different capacity
• Humidity Chambers
• Environmental Stability Tester
• Oscillating Disc Rheometer
• Data analyser for Strain measurements
• Facility for Atomic Absorption & Emission Checks
• Ultrasonic Flaw Detector
• Micro Hardness tester for rubber

Software Tools

•  Unigraphics NX/Team Center
•  MSC Nastran I Patran I Fluent
•  Catia V5 
•  MSC Fatigue
•  Adams, Easy5
•  CFD (Ansys Fluent), CFD ++
•  MSC Product Suite including Nastran
•  Altair Hyperworks Suite which includes Hypermesh, Optistruct,Radios
•  Dytran, Sofy
•  AutoCAD, Matlab
• IBM Rational
•  LDRA Testing tools
• SCADE, Display Suite

?We provide Testing Solutions to our Customers. Contact us for more details on our testing facilities.


 

General Manager
Aircraft Upgrade R&D Centre (AURDC)
Hindustan Aeronautics Limited
At Post : Ojhar Township, Nasik – 422207,
Maharashtra, INDIA

Email        :  gmaurdc.nsk@hal-india.co.in  
Website    :   www.hal-india.co.in
Phone       :  +91-2550-275464  
Fax           :  +91-2550-271965