Foundry & Forge Division Bangalore

Brief History

Welcome to the Foundry and Forge Division of Hindustan Aeronautics Limited.

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 Products for 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 it’s sister Divisions, supplies products to various domestic customers as well as global Aircraft /Aero-engine primes and Aircraft System manufacturers.

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

AS9100 D
NADCAP (Non Destructive Testing)
NADCAP (Heat Treatment)
ISO14001 (Environment Management)
ISO50001 (Energy Management)
ISO/IEC 17025:2005 (NABL) Certifications in the following areas
Customer approvals from Rolls Royce, GE, UTA

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 manpower of skilled and experienced workmen and qualified engineers. The Division spares no effort to impart professional and technical training to constantly update their skills and capabilities.

Product Engineering

This full-fledged and well-equipped Engineering Department, with its highly qualified and experienced professionals, acts as a functional interface between our customer and manufacturing departments, rendering technical support. The department is also responsible for process optimization and troubleshooting to ensure total and consistent conformance of quality of products to customer specifications.

Tooling

The combination of men and machine - the technology of CAD/CAM adapted and applied by the well-trained hands of experienced personnel - naturally results in precise dimensional accuracy for dies & patterns.

Heat Treatment

The Division is NADCAP accredited for Heat Treatment. 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 Vaccum heat treat furnace with gas quenching facility.

Other Supporting Facilities:

Alloy fabrication
Sand Rapid Prototype Machine (Additive Layer Manufacturing)
NDT facilities – MPI, FPI, 3D Scanner, Digital Radiography, Ultrasonic Testing

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
Vendors interested to provide the above services may please contactSenior Manager (Outsourcing) at 080-22321343 / 1371 ;

outsourcing.fnf@hal-india.com

National & International Approvals

Awards:
- Best vendor award from BHEL, Ordnance Factory
- National Metallurgist Awards - 07
- Green Foundry Award
- International Diamond Star Award in the realm of Customer Satisfaction
- 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
- Raksha Mantri Award for Excellence in Indigenization
IPRs:
- Patents / Copyrights filed - 14
- Patents / Copyrights awarded – 05

Castings

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 Aluminium 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 Aluminium Alloys, Steels and Vacuum Melted Nickel Alloys

Infrastructure

Automated Moulding 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 Aluminium 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

Product Range

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

ALUMINIUM ALLOY CASTINGS	Gravity / Low Pressure Sand	1500x1000x100	±1 to ±4	400	6 to 25
ALUMINIUM ALLOY CASTINGS	Gravity Die	500x500x100	±0.5 to ±1.5	20	6 to 12

MAGNESIUM ALLOY CASTINGS	Gravity / Low Pressure Sand	1000x1000x600	±1 to ±4	120	8 to 25
MAGNESIUM ALLOY CASTINGS	Gravity Die	1000x600x100	±0.5 to ±3.0	100	6 to 18

INVESTMENT CASTINGS	Air Induction Melting	Melting Capacity: 25 - 75 Kgs 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
INVESTMENT CASTINGS	Vacuum Induction Melting	Melting Capacity: 15 – 25 Kgs 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

General Forgings

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.

Infrastructure

A 3000-tonne hydraulic press
A 10-tonne Counter blow hammer with a 500-tonne clipping press
1 tonne gravity Drop hammer
Pneumatic hammers of 1500 kg, 1000kg, 500 kg and 150 kg capacities.
Cutting machines
Battery of electrical resistance pre-heating furnaces
Shot blasting machine
Heat treatment furnaces for hardening, tempering, solutionising, ageing, normalising and annealing
Process and fettling shops

Unique Capabilities

Forgings in all wrought alloys
Open forgings, closed die forgings and Saddle forged rings

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

Precision Forgings

A combination of state-of-the-art facilities and traditional hand skills has enabled the Precision Forgings Section to engineer quality into its high technology products. The process and inspection support has been designed around production of precision forgings to close tolerance.

Infrastructure

Friction screw presses - capacities of 2000 tonnes, 500 tonnes and 300 tonnes
3200T and 1000-tonne direct drive screw presses.
A 250-tonne horizontal upsetter
Abrasive blasting equipment
Vibratory finishing mills
Process shop for degreasing, etching, electropolishing and size-etching operations
Fluroescent 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-gaugung 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

Powder Metallurgy

The Powder metallurgy unit is unique in its capability to manufacture a range of sintered friction and anti-friction materials such as Copper and Iron-based brake pads and bimetallic anti-friction bearings and bushes for aircraft. 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, Continuous pusher furnaces
Unique dynamometer testing facility for assessing performance characteristics of friction materials and brake pads

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

Rubber Products

Precision rubber items and metal rubber bonded components such as gaskets, seals, o-rings, bellows, sleeves, diaphragms, and shock mounts are manufactured to stringent aeronautical standards. A range of materials including Nitrile, Neoprene, Silicone, Fluorocarbon and Flurosilicone rubbers to suit operational requirements of aircraft or helicopters in the areas of gear boxes, fuel systems, engines, electrical circuits, vibration damping and structures are manufactured.

Infrastructure

Hydraulic presses up to 150 ton capacity with automatic temperature and time control
Roll mixing mills
Extruder
Hot air ovens

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

The Ring Rolling facility has a state-of-the-art Ring Rolling mill incorporating the latest technology including computerised 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 defence and aerospace applications, with the close control of hot working and heat treatment process parameters.

Infrastructure

Computer controlled Ring Rolling mill with 100 tonne radial force and 63 tonne axial force.
Electrically heated low and high temperature pre-heating furnaces (up to 2.2 metre diameter)
A 800-tonne capacity ring expander for cold expansion of Aluminium Alloy rings
Preform making facility on 3000 tonne and 1500 Tonne Hydraulic Presses
Raw material cutting facility up to 400 mm diameter

Unique Capabilities

Rolled rings in all wrought alloys including super alloys
In-house facilities for post-rolling operations including Heat treatment, Nondestructive and Destructive tests.
Ring expansion or compression for relief of residual stress in Aluminium alloy rings
Rolling of rings with either or both internal/external profiles.

Product Range

	Mill 1(100/63T)			Mill 2(200/250T)
Alloy	OD (mm)	HT (mm)	I/P Wt (Kgs)	OD (mm)	HT (mm)	I/P Wt (Kgs)
Aluminium	3000	300	225	3000	500	1000
Steels	2000	300	1200	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
- Non -destructive testing
- 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:

Manager (Marketing) at 080-22323132 / 2911 ; cs.fnf@hal-india.com

The General Manager
Hindustan Aeronautics Limited
Foundry & Forge Division
Bangalore Complex
PB No.1791, Vimanapura Post
Bangalore 560 017
India
Telephone: +91- 80 - 22322630 / 22314610
Fax:           +91 - 80 - 22315521

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