Foundry & Forge Division Bangalore
  • About Us
  • Facilities
  • Outsourcing
  • Awards
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Brief History

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, Brake pads and Rubber Products for critical applications such as Aeronautics, Space, Defense, Locomotive, Earth mover and other engineering industries. Advanced Technology, Quality, Reliability and highly skilled workforce have enabled the Division to turn out quality components meeting and exceeding customer requirements. Foundry & Forge Division, besides catering to its sister Divisions, supplies products to various domestic customers as well as global aerospace OEMs.

Our Mission

The mission of Foundry & Forge Division is to deliver competitive products and services that meet or exceed our customers' expectations. We shall achieve our mission by:

•    Understanding customers' need
•    Developing our 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
 

Certificates

Rolled Rings
Rolled Rings
The Division has two state-of-the-art computerized Ring Rolling mills with laser measuring device. The Ring mills are capable of manufacturing plain and profiled rolled rings in variety of materials such as Steel, Nickel, Titanium and Aluminium. The Division has been supplying rolled rings to global civil aerospace, Defence and Space application.
Infrastructure:-
  • Ring rolling mill 1 - 100 tonne radial force and 63 tonne axial force.
  • Ring rolling mill 2 - 400 tonne radial force and 200 tonne axial force.
  • Presses for preform manufacturing – 5000 tons and 1500 tons capacity
  • Electrically heated pre-heating furnaces
  • A 800-tonne capacity ring expander for cold expansion of Aluminium Alloy rings
Forgings
Forgings
The Division manufactures closed die forgings in various Aluminium, Steel, Titanium & Nickel based 
alloys in many complex configurations for structural and gas turbine applications. The Division also 
manufactures ‘Near Net’ shape aero engine compressor blades in Aluminium, Titanium and Nickel 
based super alloys. CAD, CAM, CMM & simulation techniques are extensively used in the design, 
manufacture and inspection of both components and tooling.
Infrastructure:-
  • 5000 automated hydraulic press
  • 3000-tonne hydraulic press
  • A range of screw presses up to 3200 Tons
  • A range of pneumatic hammers up to 1500 kgs
  • 10-tonne Counter blow hammer 
  • 1 tonne gravity Drop hammer
  • Battery of electrical resistance pre-heating furnaces
  • Heat treatment furnaces for hardening, tempering, solutionising, ageing, normalising and annealing.
Castings
Castings
The Division manufactures Investment Castings in Aluminium, Steel & Nickel alloys and Sand 
Castings in Aluminium & Magnesium alloys.
Infrastructure
Sand Castings
  • Full-fledged automated foundry with moulding line and core shooters
  • Low Pressure Sand Casting machine
  • Flux less melting facility
  • Fluro-anodising facility for cleaning of oil passages
  • Bottom Drop Quench Heat Treatment furnaces
  • Sand Reclamation System
Investment Castings
  • Wax pattern injection machines
  • Robotic Ceramic Shell making facility with High Speed Shell Drying System
  • Vacuum and Air induction melting furnace
  • NADCAP approved Vacuum/Controlled atmosphere heat treatment furnace
Powder Metallurgy
Powder MetallurgyThe Powder Metallurgy unit is the exclusive unit in the Country to produce a range of Copper and Iron based Metallo ceramic friction Material Brake pads, Discs and Organic Brake pads for Aircraft applications. Brake pads are developed and qualified by elaborate tests to meet the most stringent Airworthiness requirements. The DGAQA and DGCA have approved the unit for design, development, manufacture and testing of military and civilian aircraft brake pads.
Infrastructure
  • Twin roller pot mills and double cone blenders for powder mixing.
  • 100, 250, 500, 1500 & 3000 tonne capacity hydraulic powder compacting presses.
  • Hydrogen atmosphere pressure sintering Bell furnaces and Pusher sintering furnaces.
  • Unique dynamometer testing facility for assessing performance characteristics of friction materials and brake pads.
Rubber Products
Precision Rubber and Metal Rubber components such as Gaskets, Seals, O Rings, Sealings, Grommets, Bushes and Spigot Fittings are manufactured in the Division, meeting stringent Aeronautical Standards. They are produced in a range of Elastomeric materials such as Nitrile, Neoprene, Silicone, Fluorocarbon and Flurosilicone suiting operational requirements of aircraft or helicopters in the areas of gear boxes, fuel systems, engines, electrical circuits, vibration damping and structures.
Infrastructure
  • Hydraulic presses up to 150 ton capacity with automatic temperature and time control.
  • Roll mixing mills.
  • Extruder.
  • Hot air ovens.
Shape Memory Products
Shape Memory Products
Shape Memory products can remember their shape and revert back to their original shape when they attain Transformation Temperature. The Division has entered into this technically challenging niche area as a strategic self-reliance measure to develop and manufacture sophisticated shape memory products.
Infrastructure 
  • Vacuum induction melting furnace
  • Vacuum arc re-melting furnace
  • Hot rolling mill
Supporting Facilities
Well-equipped support facilities have given a fillip to the core competence of the Foundry & Forge Division. Complementing the Division's comprehensive infrastructure is its skilled and experienced manpower. The Division constantly imparts management and technical training to update their skills and capabilities.
Product Engineering
Product Engineering
Full-fledged and well-equipped Engineering Department, with its highly qualified and experienced engineers, acts as a Nodal Agency for design & development of customized products and feasibility study. It acts a functional interface between customer and production departments and provides technical support in optimizing the process parameters. The team extensively uses virtual manufacturing with computer aided simulation such as Simufact, Deform, Procast etc to design the efficient process at optimum cost.
Heat Treatment
The Division’s Heat Treatment facility is NADCAP accredited besides approved by various global aerospace OEMs. The two Heat Treatment sections, one each in the Foundry and Forge shops are equipped with electrically heated furnaces (up to 2.2 meters diameter) with advanced temperature controllers and recorders for a range of heat treatments from solutionising and ageing to hardening and tempering, besides annealing and normalizing. Among the other facilities is the 1 m diameter by 1 m depth Vacuum heat treat furnace with gas quenching facility. The Division also has Vacuum Induction Melting, Vacuum Arc Remelting Furnace and an advanced automated heat treatment facility is being set up.
Other Supporting Facilities:
Other Supporting Facilities:
  • Alloy fabrication for Castings
  • Sand Rapid Prototype Machine (Additive Layer Manufacturing) for tool prototype and validation
  • Magnetic Particle Inspection
  • Fluorescent Penetrant Inspection
  • Etching
  • 3D Scanning
  • Digital Radiography
  • Immersion Ultrasonic Testing
  • In-house laboratory for all the Division’s testing needs
  • F & F Division is looking out for outsourcing partners in the following areas:
    • Rough machining of Rolled rings & Forgings
    • Machining and polishing of Aerofoil forgings
    • CNC machining of forging dies
    • Fabrication of casting tooling
    • Wire cutting and water-jet cutting
    • Aircraft Brake pad machining
    • Gamma radiography
    • 3D scanning and reporting
    • Additive Layer Manufacturing – Wax and Metal
    • Ceramic Cores o Blanking
    • Manufacturing of Elastomers
  • Vendors interested to provide the above services may please contact:
Chief Manager (Planning & Outsourcing)
Phone: 080-22322135 / 1371 ;
Email: nk.ramanamurthy@hal-india.co.in
 
National & International Approvals
  •  Awards:
    • International Diamond Star Award in the realm of Customer Satisfaction
    • Raksha Mantri Award for Excellence in Indigenization
    • Best vendor award from BHEL
    • Best vendor award from Ordnance Factory
    • National Metallurgist Awards - 07
    • Green Foundry Award
    • Non Ferrous Best Performance Award by IIM
    • Production Technology Award from AeSI
    • Indigenization of Aeronautical Award by AeSI
    • Casting of the year award from IIFM
    • Excellent laboratory award from NIIS
    • Dr Mahadevan Memorial Award to Factory Medical Superintendent
    • National Failure Analyst from Society of Failure Analysis
    • Women Excellence Award
  •  IPRs:
    • Patents awarded / filed – 01 / 14
    • Copyrights awarded / filed – 19 / 21

Castings

castingThe Division manufactures Investment Castings in Aluminium, Steel & Nickel alloys and Sand Castings in Aluminium & Magnesium alloys.
Unique Capabilities
Sand Casting
  • Capability to manufacture castings to Grade B/ Grade C as per E-155 requirement with wall thickness of 2.5mm & narrow cast oil passages of 4-10 mm dia
  • Capability to cast Volute and Aerofoil profiles
  • Thin walled, intricate, large dia and large surface area Sand castings with narrow as cast internal oil passages for helicopters and other aerospace applications
 Investment Castings
  •  Thin walled, intricate and near net shape castings for Airframe, Avionics And Aeroengine applications with close dimensional tolerances
  • Equi axed castings with high temperature properties


Product Range
 

Material

Process Max Dimension Tolerance in mm (range) Weight in kg. Surface finish in um.
 

SAND CASTINGS - ALUMINIUM

Gravity /  Low Pressure Sand 

1500x1000x100

±1 to ±4

400          

6 to 25

Gravity Die      

500x500x100

±0.5 to ±1.5

20

6 to 12

 

AND CASTINGS - MAGNESIUM

Gravity /   Low Pressure Sand 

1000x1000x600

±1 to ±4

120

8 to 25

Gravity Die      

1000x600x100

±0.5 to ±3.0

100

6 to 18

 

INVESTMENT
CASTINGS

Air/Vacuum Induction Melting

400 mm dia x 400 mm height

±0.3 mm

Ni: 0.01 to 6

Steel: 0.01 to 12

Al: 0.01 to 2

3.2

Forgings

Forgings
The Division manufactures closed die forgings in various Aluminium, Steel, Titanium & Nickel based alloys in many complex configurations for structural and gas turbine applications. The Division also manufactures ‘Near Net’ shape aero engine compressor blades in Aluminium, Titanium and Nickel based super alloys. CAD, CAM, CMM & simulation techniques are extensively used in the design, manufacture and inspection of both components and tooling.


Infrastructure

  • 5000 automated hydraulic press
  • 3000-tonne hydraulic press
  • A range of screw presses up to 3200 Tons
  • A range of pneumatic hammers up to 1500 kgs
  • 10-tonne Counter blow hammer 
  • 1 tonne gravity Drop hammer
  • Battery of electrical resistance pre-heating furnaces
  • Heat treatment furnaces for hardening, tempering, solutionising, ageing, normalising and 
annealing

 
 Unique Capabilities

  • Complex forgings including aerofoil shapes in all wrought alloys 
  • Open die forgings, closed die forgings and Saddle forged rings
  • Custom built equipment for forging, processing and inspection of precision forgings especially compressor and turbine blades


Product Range

Process Size in mm (max) Weight in kg. Tolerance in mm (range) Surface finish in um.

Open Die Forgings

Aluminium    Alloys

800 x 800

175 ± 5 10 to 15
Magnesium    Alloys

600 x 600

100 ± 5 10 to 15
Steel

500 x 175

300 ± 5 15 to 20
Closed    Die Forgings
Aluminium    Alloys 650 x 200 50 ± 0.5 to    ± 2 3 to 5
Magnesium    Alloys 400 x 400 10 ± 0.5 to    ± 2 3 to 5
Steels 300 x 300 40 ± 0.5 to    ± 3 6 to 8
Aero-engine blades
Aluminium    Alloys 400 x 250 3.5

+0.15 / -0.00

<1

Nickel Alloys

150 x 70 1.0 +0.15 / -0.00

<1

Steels 350 x 150 2.0

+0.30 / -0.00

<1

Titanium Alloys

250 x 100 1.2

+0.30 / -0.00

<1

Fan Blades for Gas Turbines (Al)

800 x 200

05

±1

3 to 5

Close Die Near net forgings

Aluminium    Alloys

300 x 300 

20 ± 1 3 to 5

Nickel Alloys

200 x 200  15

±0.5 to ±1.0

6 to 8

Steels 250 x 250 20

±0.5 to ±1.0

6 to 8

Titanium Alloys

200 x 200 15

±0.5 to ±1.0

6 to 8

Powder Metallurgy

Powder Metallurgy
The Powder Metallurgy unit is the exclusive unit in the Country to produce a range of Copper and Iron based Metallo ceramic friction Material Brake pads, Discs and Organic Brake pads for Aircraft applications. Brake pads are developed and qualified by elaborate tests to meet the most stringent Airworthiness requirements. The DGAQA and DGCA have approved the unit for design, development, manufacture and testing of military and civilian aircraft brake pads.
Capabilities 
  • The entire technology for manufacturing Brake pads for most of India’s Armed forces operated aircraft has been indigenously developed by the Division.
Product Range

Different sizes and shapes of Copper and Iron-base metalloceramic friction pads, and resin-based organic brake pads.

Rubber Products

Rubber Products
Precision Rubber and Metal Rubber components such as Gaskets, Seals, O Rings, Sealings, Grommets, Bushes and Spigot Fittings are manufactured in the Division, meeting stringent Aeronautical Standards. They are produced in a range of Elastomeric materials such as Nitrile, Neoprene, Silicone, Fluorocarbon and Flurosilicone suiting operational requirements of aircraft or helicopters in the areas of gear boxes, fuel systems, engines, electrical circuits, vibration damping and structures.

Unique Capabilities

  • Moulded products with close tolerance limits of ± 0.02 to + 0.1 mm up to a size of 200 * 200 * 200 mm.
  • Development of rubber compounds to any specifications and pre-determined requirements.


Product Range

Product Size (max) in mm
'O' Rings, Seals, Grommets Up to 220 ID * 10 mm
Bushes, Bellows, Boots, Pads, Washers, Gaskets, Metal-Bonded Items Up to 300 * 300 * 10 mm Up to 150 * 150 * 50 mm

Rolled Rings

Rolled Rings
The Division has two state-of-the-art computerized Ring Rolling mills with laser measuring device. The Ring mills are capable of manufacturing plain and profiled rolled rings in variety of materials such as Steel, Nickel, Titanium and Aluminium. The Division has been supplying rolled rings to global civil aerospace, Defence and Space application.

Capabilities
  • The Division has end-to-end facilities for complete manufacturing of rolled rings including preform manufacturing, Rolling, Heat treatment and testing.
  • Rolled rings are being manufactured in all wrought alloys including super alloys.
  • Ring expansion or compression for relief of residual stress in Aluminium alloy rings.


Product Range

  Mill 1(100/63T) Mill 2(400/200T)
Alloy OD(mm) HT(mm)

I/P Wt(Kgs)

OD (mm) HT (mm) I/P Wt (Kgs)
Aluminium 3000 300 225 3500 500 1000
Steels 2000 300 500 3000 500 2000
Titanium 1500 300 200 2000 500 500
Nicket 500 85 50 2000 500 250
  • Full Fledged R&D laboratory facility  - Nodal Agency for testing and consultancy support in materials.
  • Areas of Expertise:
    • Metallurgical testing & Characterization
    • Chemical analysis
    • Mechanical testing
    • Calibration – Force and Thermal
    • Materials Research & Development (including indigenization)
    • Technical Consultancy on Materials
    • Accident/Incident Failure Analysis
    • Design data generation
    • Training programs on NDT (including failure analysis) and Heat treatment
 
  • Customers interested in availing the above testing services may please contact:
Senior Manager (Marketing) Phone: 080-22323132 / 2911
Email: cs.fnf@hal-india.co.in
Please visit the following webpage for further details on our laboratory:
www.hal-india.co.in/Central%20Materials%20and%20Processes%20Laboratory%20%20NDT%20Centre/M__154
The Executive Director
Foundry & Forge Division
Hindustan Aeronautics Limited
Bangalore Complex PB No.1791, Vimanapura Post
Bangalore 560 017
India
Telephone: +91- 80 - 22322630 / 22314610
Fax: +91 - 80 - 22315521

E-mails:
Executive Director - venkatesh.ms@hal-india.com
Marketing:
Exports business  -  export.fnf@hal-india.com
Telephone : +91 80-22315801 / 22323132
Domestic business  -  mktg.fnf@hal-india.com
Telephone: + 91 80-22314337 / 22322911