Hindustan Aeronautics Limited

HISTORY
HAL was established as Hindustan Aircraft Limited in Bangalore on 23 December
1940 by Walchand Hirachand who became Chairman of the company. The
companies office was opened at a bungalow called "Eventide" on Domlur Road.
The organization and equipment for the factory at Bangalore was set up
by William D. Pawley of the Intercontinental Aircraft Corporation of New York,
who had already established Central Aircraft Manufacturing Company (CAMCO) in
partnership with Chinese Nationalist government. Pawley obtained a large
number of machine-tools and equipment from the United States.
The Indian Government bought a one-third stake in the company and by April
1941 by investing 25 lakhs as it believed this to be a strategic imperative. The
decision by the government was primarily motivated to boost British military
hardware supplies in Asia to counter the increasing threat posed by Imperial
Japan during Second World War. The Kingdom of Mysore supplied two directors,
Air Marshal John Higgins was resident director. The first aircraft built was
a Harlow PC-5 on 2 April 1942, the government announced that the company had
been nationalised when it had bought out the stakes of Seth Walchand Hirachand
and other promoters so that it could act freely. The Mysore Kingdom refused to
sell its stake in the company but yielded the management control over to the
Indian Government.

INTRODUCTION
HAL is an Indian state-owned aerospace and defense company
in Bangalore, India. It is governed under the management of the Indian
Ministry of Defence.
The government-owned corporation is primarily involved in the operations
of the aerospace and is currently involved in the design, fabrication and
assembly of aircraft, jet engines, Helicopters and their spare parts. It has
several facilities spread across India including Nasik, korwa, Kanpur,
koraput, Bangalore, Hyderabad and Kasaragod. The HAL HF-24
Marut fighter-bomber was the first fighter aircraft made in India.
HAL DIVISIONS IN BANGLORE:
 Aircraft division Bangalore
 Overhaul division Bangalore
 Aerospace division Bangalore
 Engine division Bangalore
 IGMT Division Bangalore
 Aircraft services division
 Foundry and forge division
 Facilities management division

CUSTOMERS
DEFENCE & SPACE CIVIL

Indian Air Force Border Security Force

Indian Army Oil & Natural Gas Cooperation of
India
Indian Navy Govt. of Karnataka
Indian Coast Guard Govt. of Jharkhand
Indian Space Research Organization Govt. of Maharshtra
Defence Research & Development Geological Survey of India
Organisation
Ordnance Factory Board Bharat Heavy Electricals Ltd.
 Adour MK- 871

INTRODUCTION
HAL is the manufacturer of ADOUR 871 engine which is used in the trainer Hawk
air craft. Adour engine is a turbofan engine which is similar to turbojet engines
with additional by pass system. Here the fully compressed air enters combustion
chamber section while uncompressed enters by pass unit which either joins at
turbine or is exhausted to atmosphere via hot zone. The advantage of by pass
system is that it increases turbine efficiency and decreases turbine gas
temperature thereby increasing the lift and efficiency of turbine. It also cools
combustion zone and hot end section of engine. Common jet engine used in the
most of the aircraft is turbo fan engine type.
About Engine Division
Engine division has mainly 3 different stages such as:

 Raw material shop

 Manufacturing shop
 Testing section
 Assembly section

So now let us see the each shop as what they contain and what is done there in
each shop as per the requirement for the materials in each division for assembly
of each engine.

Manufacturing shop:

In this shop the raw materials are taken and done into finish goods as per the
required dimension using CNC, and special purpose machine. In manufacturing
shop there are different places like sheet metal & welding shop, gear shop, blade
shop, veins shop, cellular shop, NDT, processing shop, heat treatment shop.

Sheet metal and welding shop

Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet
metal is one of the fundamental forms used in metal working and it can be cut
and bent into a variety of shapes. Countless everyday objects are fabricated from
sheet metal. Thicknesses can vary significantly; extremely thin sheets are
considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered
"structural steel." Inconel and stainless steel alloys. The Inconel [nickel-chromium-
iron] alloys are frequently used in turbine engines because of their ability to
maintain their strength and corrosion resistance under extremely high
temperature conditions.

Welding is a fabrication or sculptural process that joins materials, usually

metals or thermoplastics, by using high heat to melt the parts together and
allowing them to cool causing fusion. There are different types of welding done
here such as: TIG welding (tungsten inert gas) or orbital welding, circumferential
welding.

Circumferential welding:

Specification of machine:

 Make: BODE
 Supplier: miller-syncrowave
 Type: AC/DC
 Current: 5 to 50amps
 Weld torch: HELIARC-HW27
 Type: water cooled
 Cooling system: WATERMATETMA
  Electrode: 2% thoriated tungsten
 Manual torch: WNI-17
 Type: air cooled
 Current: 5 to 150amps
 Shielding gas: HP argon gas
 Max diameter: 960mm
 Till angle:0-135(degree)
 Max boom travel: 1000mm
 Max boom up & down travel: 500mm
 Wire feeder: jet line
 Range: 1-20IPM

Orbital welding:

Orbital welding is a specialized area of welding whereby the arc is rotated

mechanically through 360° (180 degrees in double up welding) around a static
workpiece, an object such as a pipe, in a continuous process. Argon gas is used
here. Shakti engine manipuhold components are done. Welding temperature is
1400C. Orbital welding is also a type of TIG welding.
Resistance welding:

Electric resistance welding (ERW) refers to a group of welding processes such as

spot and seam welding that produce coalescence of faying surfaces where heat to
form the weld is generated by the electrical resistance of material combined with
the time and the force used to hold the materials together during welding.

Hydraulic Press Machine

A hydraulic press is a machine press using a hydraulic cylinder to generate a

compressive force. It uses the hydraulic equivalent of a mechanical lever, and was
also known as a Bramah press after the inventor, Joseph Bramah, of England. He
invented and was issued a patent on this press in 1795.

 Capacity: 275 tons

  Action: triple action
 Application: deep drawing machine
 Component: deflector(Shakti engine)

Cellular shop

Cellular shop is the place where laser drilling, electronic CNC EDM Machine, laser
cutting machine, 7 axis pipe bending machines are there. Here in this shop most
the components manufactured are small components they work on air flow pipes,
NGV’S, Coolant air flow pipes and fuel flow pipes.

Laser drilling machine:

Laser drilling is the process of creating thru-holes, referred to as “popped” holes

or “percussion drilled” holes, by repeatedly pulsing focused laser energy on a
material. The diameter of these holes can be as small as 0.002” (~50 μm).
Percussion laser drilling is very similar to single-shot laser drilling, and works by
firing pulses of a laser at one specific spot of a material. As with the above
method, it melts away a material's surface layer by layer, leaving behind a rough
surface or clean thru-holes.

Specification:

 Model: laserDyne 790ES

  Landed cost: 50354600.00
 Control: system 94P control
 Work center: 953
 Laser power: 200w
 No of axis: 6
 X-axis: 1040mm
 Y-axis: 1040mm
 Z-axis: 1040mm
 C-axis:+/-45(degree)
 D-axis:+/-135(degree)
 A-axis:+/-360(degree)
 Rotation speed:0-5rpm
 Laser type: Nd-YAGLaser
 Laser wavelength:1064mm
 O2 gas is used in mandeling

Laser Cutting Machine:

Laser cutting is a technology that uses a laser to cut materials, and is typically
used for industrial manufacturing applications, but is also starting to be used by
schools, small businesses, and hobbyists. Laser cutting works by directing the
output of a high-power laser most commonly through optics.
When cutting stainless steel or aluminum, the laser beam simply melts the
material, and high pressure nitrogen is used to blow the molten metal out of the
kerf. On a CNC laser cutter, the laser cutting head is moved over the metal plate
in the shape of the desired part, thus cutting the part out of the plate.

Specification:

 Model: rofin-platino
 Point of metal cutting temperature: 3000c
 Axis of machine: 2 axis
 Gas: helium inert gas
 Nitrogen used to flush the excess molten material
 It is a closed loop system
 Cut limit:
 Alloy steel: 6-7mm
 Mild steel: 20mm
 laser : CO2 laser
 vacuum pressure: -4 TOR