Welcome to Foundry & Forge Division Bangalore of HAL (Bangalore Complex).
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.
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
- 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
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.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.
- 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: rajiv.datt@hal-india.co.in
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 | ||||
| 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 | ||||
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 |
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.
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 |
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:
GENERAL MANAGER(F&F)
Foundry & Forge Division
Hindustan Aeronautics Limited
Bangalore Complex PB No.1791, Vimanapura Post
Bangalore 560 017
India
Telephone: +91- 80 – 22322630
+91-80-22314610
Fax: 08022315521
E-mail: praveen[dot]b[at]hal-india[dot]co[dot]in