Foundry & Forge Division Bangalore

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Castings

The 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
SAND CASTINGS - ALUMINIUM	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
AND CASTINGS - MAGNESIUM	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

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

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

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

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