INTERNSHIP REPORT

A report submitted in partial fulfilment of the requirements for the Award of degree of

BACHELORS OF TECHNOLOGY
In
Aeronautical Engineering.

By
Rahul Lohar (A719104917010)

Amity University, Mumbai - Pune Expressway, Bhatan, Post – Somathne, Panvel, Mumbai, Maharashtra
410206
 Amity University Mumbai
Amity Institute of Tata & Technology (AIT)
 ABSTRACT
HINDUSTAN AERONAUTICS LIIMITED(HAL), FOUNDRY AND FORGE DIVISION
HAL Old Airport Rd, Vinayaka Nagar, Vimanapura, Bengaluru, Karnataka 560017

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, Defence, 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 its sister Divisions, supplies products to various domestic
customers as well as global Aircraft /Aero-engine primes and Aircraft System manufacturers.

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
OBJECTIVE
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

METHODOLOGY
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.

OPPORTUNITY
Permission for internship training given on no-pay, no-fee basis. This comprises strict observance and
learning the various procedures carried out in the Foundry and Forge division.

FINDINGS OF THE REPORT

A detailed description of the processes carried out in the Foundry and Forge division of Hindustan
Aeronautics Limited (HAL), Bangalore, with a list of the products manufactured, and main suppliers.
The report also consists of the major manufacturing areas visited by the four of us, and all the eminent
knowledge gained with the help of each department head and the people working in them.
 WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES

1ST WEEK
S.NO DATE DAY DEPARTMENT
1. 03.06.2019 Monday Powder Metallurgy Shop and Ferrous Foundry
2. 04.06.2019 Tuesday Non-Ferrous Foundry
3. 06.06.2019 Thursday Pattern Shop and
Magnesium Foundry
4. 07.09.2016 Friday Ring Rolling Shop
5. 08.06.2019 Saturday Rubber Shop

2ND WEEK
S.NO DATE DAY DEPARTMENT
1. 10.06.2019 Monday Precision Foundry
2. 11.06.2019 Tuesday General Forge
3. 12.06.2019 Wednesday Die Shop and
Machine Shop
4. 13.06.2019 Thursday Shape Memory and
Development Department
5. 14.06.2019 Friday Marketing and
CMPL Lab
6. 15.06.2019 Saturday Quality Control and Stores
Foundry & Forge Division Bangalore
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 Vacuum 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
 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:

 Aluminium 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
 GENERAL FORGE

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

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
 Fluorescent 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-gauging 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-based 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 Fluro silicone 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.
 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)
 An 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, Non-destructive 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.

HAL FOUNDRY AND FORGE

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

Figure 1 Non-destructive Testing

 Figure 2 Titanium Rods

Heat Treatment

Annealing Heat Treatment

Heat treatment process is heating the material above the critical temperature.
heat treatment that alters the physical and sometimes chemical properties of a material to increase its
ductility and reduce its hardness, making it more workable.
It involves heating a material above its re-crystallization temperature, maintaining a suitable temperature,
and then cooling.
Purpose:
1. To reduce hardness.
2. To relieve internal Stresses.
3. To improve machinability.
Advantages
It softens the steel. It reduces thermal stresses which occur due to temperature gradient. It enhances and
improves the machinability of steel. It increases the ductility of steel. It enhances the toughness of steel. The
grain size of the steel is refined.

Normalizing

Provide uniformity in grain size and composition throughout an alloy. Uniform material properties as
produced with an.
Heating the steel just above its upper critical point creates grains much smaller than the previous grains,
which during cooling, form new grains with a further refined grain size. The process produces a tougher,
more ductile material, and eliminates columnar grains.

Hardening

Hardening involves heating of material, keeping it at an appropriate temperature until all pearlite is
transformed into austenite, and then quenching it rapidly in water, oil & polymer. The temperature at which
austentizing rapidly takes place depends upon the carbon content in the steel used. The heating time should
be increased ensuring that the core will also be fully transformed into austenite.
Improvement of the mechanical properties
Increase in the level of hardness, producing a tougher, more durable item.

Tempering

Untempered martensitic steel, while very hard, is too brittle to be useful for most applications. Most
applications require that quenched parts be tempered. Tempering consists of heating steel below the lower
critical temperature, (often from 205 to 595 ˚C, depending on the desired results), to impart some toughness.
Higher tempering temperatures (Till 700 ˚C, depending on the alloy and application) are sometimes used to
impart further ductility, although some yield strength is lost.

DAY TO DAY ACTIVITIES

POWDER METTALURGY SHOP AND FERROUS FOUNDRY

PRODUCTS MANUFACTURED-
Iron-based Brake Pads
Brake pads are developed for high energy brakes for a variety of military and civilian aircrafts and are
qualified by dynamometer testing in accordance with MIL-W-5013, TSO-c 26 and FAR 25-735.
Metalloceramic pads are manufactured in Russia and India.
Carbon-Carbon pads are manufactured in USA.
Brake pads can be Iron-based or Copper-based.

Iron-based Brake Pads are used for aircrafts like-

 AN-32
 Islander
 Jaguar
 MIG-29
 MIG-27
Copper-based brake pads are used for-
 DORNIER 228-220
 KIRAN MK-II
 HAL AURO-748
 Boeing 737-200
 Main Battle Tank

The processing and testing facilities include pressure sintering furnace, computerized friction and wear
testing and brake dynamometer.
Iron based Pressure sintered Base linings
The manufacturing process includes-
1. Powder conditioning/ dry and wet mixing of metal powder, ceramic powder and solid
lubricant powder
2. Press Compaction
3. Formation of Green Compact
4. Assembly with Nickel plated back plates
5. Stacking of pad assemblies for Press Sintering
6. Hydrogen pressure sintering
7. Bend Test and Chemical Analysis
8. Repressing/ coining
9. Micro-structure and hardness Test
10. Machining
11. Friction and Wear test
12. Protective painting
The Nickel-plated back plates are formed by the BLANKING and PIERCING of alloy steel strip, and then
sulphamate nickel plating.
Copper Sintered Brake pads
The manufacturing process includes-
1. Powder mixing, conditioning and Blending of metal, ceramic, and graphite powders.
2. Weighing and filling of friction mix in cup assembly.
3. Loose bulk sintering
4. Press compaction
5. Hydrogen sintering
6. Chemical analysis of sintered pad
7. Repressing/coining
8. Microstructure and hardness test
9. Machining
10. Friction and wear test
Dynamometer Testing

A dynamometer, or "dyno" for short, is a device for measuring force, moment of force (torque), or power.
For example, the power produced by an engine, motor or other rotating prime mover can be calculated by
simultaneously measuring torque and rotational speed (rpm).

A dynamometer can also be used to determine the torque and power required to operate a driven machine
such as a pump. In that case, a motoring or driving dynamometer is used. A dynamometer that is designed to
be driven is called an absorption or passive dynamometer. A dynamometer that can either drive or absorb is
called a universal or active dynamometer.

Applications for Dynamometers

In addition to being used to determine the torque or power characteristics of a machine under test (MUT),
dynamometers are employed in a number of other roles. In standard emissions testing cycles such as those
defined by the US Environmental Protection Agency (US EPA), dynamometers are used to provide
simulated road loading of either the engine (using an engine dynamometer) or full powertrain (using a
chassis dynamometer). In fact, beyond simple power and torque measurements, dynamometers can be used
as part of a testbed for a variety of engine development activities such as the calibration of engine
management controllers, detailed investigations into combustion behaviour and tribology.

Laboratory Metallurgical Testing

1. Optical microscopy and Image analysis
2. Micro hardness Testing
3. Hardness Testing
4. Instrumented Chemical Analysis
 5. Ultrasonic Bond Quality Testing
Microscope used- LEO440i Scanning Electron Microscope

SINTERING PROCESS
Sintering, the welding together of small particles of metal by applying heat below the melting point. The
process may be used in steel manufacturing to form complex shapes, to produce alloys, or to work in metals
with very high melting points. In a steel-sintering plant a bed of powdered iron ore, mixed with coke or
anthracite, is ignited by a gas burner and then moved along a traveling grate. Air is drawn down through the
grate to produce downdraft combustion. As the bed moves forward, a very high heat (1,325°–1,500° C) is
generated that converts the tiny particles into lumps about 2.5 cm (1 inch) in diameter suitable for burning in
the blast furnace to convert them to steel. Sintering is also used in the preliminary moulding of ceramic
or glass powders into forms that can then be permanently fixed by firing.
The driving force in sintering is decreasing surface energy; as the sintering proceeds, adjacent particles
partially coalesce owing to viscous flow (as in glass) or to diffusion processes (as in crystalline materials),
and consequently the total surface area decreases. The result is improved mechanical and physical properties
of the material. See also powder metallurgy.

NON-FERROUS FOUNDRY

Casting of aluminium alloy –

Green sand is used along with phenol formaldehyde resin along with binder.
The casting process consists of,
 Mould-making
 Clamping
 Pouring
 Cooling
 Removal
 Fettling

Testing carried out are-

1. Chemical testing- of raw material.
 2. Microstructure testing- To observe the structure after casting.
3. Dimension inspection- Visual Inspection
4. X-ray testing – for cracks and internal defects.

CHARACTERISTICS OF ALUMINIUM

Aluminium is lightweight, has excellent strength, high thermal and electrical conductivity, high reflectivity,
good corrosion resistance, excellent workability, and attractive appearance. It can be given almost any finish.
It is nonmagnetic, nontoxic, and non- sparking. The high thermal conductivity and strength-to-weight ratio
of aluminium is a marked advantage in any application where it is desirable to conduct or dissipate heat
quickly and uniformly. On a weight basis, aluminium is the most efficient heat conductor of the common
metals.

PATTERN SHOP
Casting is a manufacturing process in which a liquid material is usually poured into a mould, which contains
a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as
a casting, which is ejected or broken out of the mould to complete the process. Casting materials are usually
metals or various time setting materials that cure after mixing two or more components together; examples
are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be
otherwise difficult or uneconomical to make by other methods.
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The
blows are delivered with a hammer (often a power hammer) or a die. Forging is often classified according to
the temperature at which it is performed: cold forging (a type of cold working), warm forging, or hot forging
(a type of hot working). For the latter two, the metal is heated, usually in a forge. Forged parts can range in
weight from less than a kilogram to hundreds of metric tons. Forging has been done by smiths for millennia;
the traditional products were kitchenware, hardware, hand tools, edged weapons, cymbals, and jewellery.
Since the Industrial Revolution, forged parts are widely used in mechanisms and machines wherever a
component requires high strength; such forgings usually require further processing (such as machining) to
achieve a finished part.

Parts that cannot be machined are casted. Forging is used when a lot of strength is required.
PROCEDURE
The Aluminium Sand-Casting Process

Green sand, which is new or regenerated sand mixed with natural or synthetic binders, is the most commonly
used material for making aluminium expendable moulds. Green sand moulds get their name from the fact
 that they are still moist when the molten metal is poured into them. The process of aluminium sand casting
using green sand and the gravity filling method can be summarized as follows:

 A mould is created by placing the mixture of sand, clay and water on a pattern (the replica of the
object to cast). Although this process can be done by hand, machinery is normally used in order to achieve
better precision of the mould. When the pattern is removed the clay will have a cavity that corresponds to the
shape of the pattern

 The sand mould has two or more parts, the upper part is known as the cope while the bottom one is
called the drag. Additional parts known as cheeks can also be used. The moulds are encased in a two-part (or
more if cheeks are used) box called a flask for protection. Before the flask is closed, any sand cores needed
to manufacture the part details are placed in the mould halves. The gating system is placed inside, and a
sprue is formed in order for the molten alloy to be fed into the cast

 The two halves are closed and clamped together and molten metal is then poured into the mould. As
the metal starts to cool and some contraction takes place, molten metal is fed in from the risers that were
placed in the casting system

 Because sand and clay do not absorb heat, the cooling time is a lot longer than that of permanent
mould or die casting. Chills (metal plates) can be inserted into the sand mould in order to help provide an
equal cooling rate throughout the cast. As a consequence of the slower cooling, there is an appreciable
decrease in the mechanical properties of alloys such as Aluminium 319 and 356, magnesium and bronze
when compared to those of the same alloys cast with the permanent or die casting methods based on the
Secondary Dendrite Arm Spacing (SDAS) value

 After a pre-set dwell time to allow the metal to solidify, the cast shake out takes place. The heat from
the molten metal that is poured into it dries out the moisture making the cast easy to crack open when the
metal has cooled
Aluminium sand-casting defects to look out for are residual oxide film, inclusion, core erosion, gas holes and
shrinkage porosity.

Sand cast aluminium components are widely used in the automotive and transportation industries including
aerospace. Parts commonly produced with sand casting include the power-train, supports, suspensions,
casings, gears and many others.

INVESTMENT CASTING
  Investment casting of aluminium most commonly employs plaster moulds and expendable patterns of
wax or other fusible materials. Plaster slurry is "invested" around patterns for several castings, and
the patterns are melted out as the plaster is baked.
 Investment casting produces precision parts; aluminium castings can have walls as thin as 0.40 to
0.75 mm. However, investment moulding is often used to produce large quantities of intricately
shaped parts requiring no further machining so internal porosity seldom is a problem. Because of
porosity and slow solidification, mechanical properties are low.
 Investment castings usually are small, and it is especially suited to production of jewellery and parts
for precision instruments. Recent strong interest by the aerospace industry in the investment casting
process has resulted in limited use of improved technology to produce premium quality castings.
Combining this accurate dimensional control with the high and carefully controlled mechanical
properties can, at times, justify casting costs and prices normally not considered practical.
 Aluminium alloys commonly used for investment castings are 208.0, 295.0, 308.0, 355.0, 356.0,
443,0, 514.0, 535.0 and 712.0.

Process

NOTES
A-B-C (Activator-Binder-Catalyst) is used for the casting process.
 The wax used is KC3898
 The software used for casting simulation are- PROCAST and MAGMA.
 The software used for design are UNIGRAPHICS and SOLIDWORKS.
 Casting Allowance for Investment is 2mm.
 The shrinkage allowance for Aluminium and Magnesium is 1.25%
 The tolerance for Investment Casting is +/-0.25 mm.
MAGNESIUM FOUNDRY

Casting processes
 Sand Casting. Magnesium alloy sand castings are used in aerospace applications because they offer a clear
weight advantage over aluminium and other materials. A considerable amount of research and development
on these alloys has resulted in some spectacular improvements in general properties compared with the
earlier AZ types.
Although there has been, and still is, a large volume of castings for aerospace applications being produced in
the older, conventional AZ-type alloys, the trend is toward the production of a greater proportion of
aerospace castings in the newer zirconium types.
Although the magnesium-aluminium and magnesium-aluminium-zinc alloys are generally easy to cast, they
are limited in certain respects. They exhibit micro shrinkage when sand-cast, and they are not suitable for
applications in which temperatures of over 95°C are experienced. The magnesium rare earth-zirconium
alloys were developed to overcome these limitations. Sand castings in the EZ33A alloy do in fact show
excellent pressure tightness. The greater tendency of the zirconium-containing alloys to oxidize is overcome
by the use of specially developed melting processes.

Magnesium, however, has other important casting advantages over other metals:
 It is an abundantly available metal
 It is easier to machine than aluminium
 It can be machined much faster than aluminium, preferably dry.

When magnesium becomes molten, it tends to oxidize and explode, unless care is taken to protect the molten
metal surface against oxidation. Molten magnesium alloys behave differently from aluminium alloys, which
tend to form a continuous, impervious oxide skin on the molten bath, limiting further oxidation. Magnesium
alloys, on the other hand, form a loose, permeable oxide coating on the molten metal surface. This allows
oxygen to pass through and support burning below the oxide at the surface. Protection of the molten alloy
using either a flux or a protective gas cover to exclude oxygen is therefore necessary.

RING ROLLING SHOP

Ring rolling is a particular category of metal rolling, in which a ring of smaller diameter is rolled into a
precise ring of larger diameter and a reduced cross section. This is accomplished by the use of two rollers,
one driven and one idle, acting on either side of the ring's cross section. Edging rollers are typically used
during industrial metal rolling manufacture, to ensure that the part will maintain a constant width throughout
the forming operation. The work will essentially retain the same volume, therefore the geometric reduction
in thickness will be compensated for entirely by an increase in the ring's diameter. Rings manufactured by
ring rolling are seamless. This forming process can be used to manufacture not only flat rings, but rings of
differently shaped cross sections as well, producing very precise parts with little waste of material.

A significant advantage of parts produced by this metal rolling process is that the forming of the material
will impart the ring with a grain orientation that gives it enhanced strength relative to most applications.
Common items produced by this process in manufacturing industry today include rings for machinery,
aerospace applications, turbines, pipes, pressure vessels, roller and ball bearing races. The following shows
the sequence of events of the ring rolling process, the part is commonly started as a metal bar cut to a certain
length.

NOTES
 1. The rolling is computer aided.
2. The rings are made of Nickel and Steel.
3. Mechanical and metallurgical testing is carried out after the rings are made.
4. Rolls-Royce engine is the major customer of the ring-rolling department of foundry and
forge.
5. USES of rings-
 Drop tank
 Engine
6. The coolant explosion is accompanied by a vast explosion of air in order to remove the steam
formed so that the position of the laser on the rolling ring is not disturbed.

TESTING CARRIED OUT IN THE RING ROLLING INSPECTION

1. Non-destructive Testing (NDT)
2. Micro- Particle Inspection
3. Ultrasonic Inspection

RUBBER SHOP
VULCANISATION
Vulcanization of rubber is a process of improvement of the rubber elasticity and strength by heating
it in the presence of sulphur, which results in three-dimensional cross-linking of the chain rubber
molecules (polyisoprene) bonded to each other by sulphur atoms.
vulcanization technique comprises the following principal stages: 
 Mixing of crude rubber with about 5-30% of sulphur (cross-linking agent) and other additives
such as:
 activator (commonly zinc oxide or stearic acid),
 accelerator (guanidine, thiazoles, dithiocarbamates, xanthates, thiurams) ,
 coagulants (acetic acid, calcium chloride),
 anti-oxidants (amines, phenolics, phosphites),
 colour pigments,
 surfactants,
 softeners (oils),
 ant-foaming agents,
  Anti-tack agents (Rosin derivates, coumarone-indene resins, aliphatic petroleum resins,
alkyl-modified phenol-formaldehyde resins).
Slow cross-linking starts at this stage. It is necessary to avoid active vulcanization during mixing,
which may cause cracks formation at the moulding stage.

 Moulding (shaping) the rubber mixture. The rubber must be shaped prior to heating stage
since cross-linking makes shaping impossible.
 Heating the mixture to 250-400ºF (120-200ºC). Increased temperature speeds up the
vulcanization process resulting in fast and complete cross-linking. C-S bonds replace C-H bonds
linking chain polyisoprene molecules. Each link is formed by one to seven sulphur atoms.

Density of cross-links must be controlled in order to prevent formation of brittle rubber.

Properties of rubber improved by vulcanization:

 tensile strength;
 elasticity;
 hardness;
 tear strength;
 abrasion resistance;
 resistance to Solvents.

PARAMETERS TO CONSIDER-
 Temperature
 Pressure
 Time

USES-
1. Engine
NOTES
1. Rubber is stored in controlled humidity and low temperature.
2. Rubber takes 24 hours for complete curing at a temperature of 230℃
3. The vulcanization process is irreversible.
4. Temperature and Time for vulcanisation of different materials –
 Nitrile Rubber (150℃, 10 mins)
 Silicone Rubber (170℃ ,15 mins)
 Fluro-silicone rubber (170℃ ,15 mins)
5. Carbon Black is used as a reinforced filler.
 Figure 3 Silicone rubber rings

PRECISION FORGE

The machines used in the precision foundry comprise of the Muller Weingarten 3200, which is a
German machine and operates on the principle of closed-die forging; and a Friction Screw Press.

The Forging temperatures used for various metals in a low and high temperature furnace are-
ALUMINIUM – 400℃ TO 450℃
STEEL – 1050℃ TO 1150℃
TITANIUM – 1150℃ TO 1180℃
NICKEL – 950℃ TO 980℃

The raw material used is BILLETS. The billets are stored in a furnace. And then fed to a bolster.

Two types of lubricants are used-

1.Oil based Graphite
2. Water based graphite.

Steel parts are subjected to –

 Short Blasting
 Sand Blasting

Spare parts of an aircraft are manufactured in this department.

NOTES-
 The aluminium parts are subjected to an vapour degreasing.
 Then, they are subjected to acid pickling.
 It is followed by cold swill/ spray wash.
 The parts are then immersed into an anodising bath.
USES-
 Rotor blades (Steel made)
 Stator blades (Titanium made)
PENETRANT INSPECTION
To observe micro cracks. It is carried out by dipping the part in water for 10 to 15 minutes.
GENERAL FORGE
OPEN DIE FORGING IS CARRIED OUT IN GENERAL FORGE.
The raw material used is Rods and Billets.
Processes carried out-
 Case Hardening
 Hardening (Rate of cooling principle)
 Tempering (increases lifespan, stability)
 Annealing (softening of the metal-to facilitate machining)
 Normalizing (to facilitate hardening)
 Heat Treatment

Heating is carried out up to the critical temperature of the metal.

Metals used in the alloy are- Aluminium, Nickel, Titanium ad Copper.
Processes carried out-
1. SOLUTIONISING (BASE ATOM IS DISTRIBUTED UNIFORMLY ALONG THE ALLOY
METAL)
2. PRECIPITATION (WATER IMMERSION IN A SUPER SATURATED SOLUTION)
3. AGEING (PROLONGED TIME IN A FURNACE AT A CERTAIN TEMPERATURE). It is carried
out at 175℃ for 10 hours.
4. CALIBRATION (MAINETNANCE AND CONDITION CHECKING)

FLOW PROCESS
 NORMALIZING
GH-10 / GH-8 Furnace
Heat- 940℃ +/- 14 ℃
Time- 1 hour 40 minutes +/- 10 minutes
Followed by air cooling.
  HARDENING
GH-10 / GH-8 Furnace
Pre heat- 660 ℃; soak for 30 mins
Rise to 899℃+/- 14℃
Soak for 1 hour 40 mins +/- 10 mins
Oil quenching in Quench Tank
The oil temperature should lie between 27 to 66℃ and not exceed 93℃

NOTE-
Oil quenching is preferred to water quenching due to distortion and viscosity. It is carried out to prevent
cracks.
Quench 707 oil is used.

The operations carried out are-

 Cheesing
 Upsetting
 Piercing
 Forging
 Heat Treatment.
Heat treatment is carried out in three types of furnaces; namely-
1. Box Type Furnace
2. Pit Type Furnace
3. Rotary Type Furnace
Low temperature furnaces range from 100℃ to 450℃
Medium temperature furnaces range from 450℃ to 650℃
High temperature furnaces range from 650℃ to 1400℃

The forged part is dipped in a polymer to avoid warpace (symmetric changes).

DIE SHOP
Blade dies are manufactured in the die shop.
Two processes take place to separate the locking lugs from the main body;
 Encapsulation
 Decapsulation

Machines used in the department are-

 CNC- Computerized Numerical Control (To make dies)
 EDM- Electrical Discharge Machining
It consists of an anode and cathode made up of copper and graphite.
Material is removed from the workpiece by a series of rapidly recurring current discharges between
two electrodes, separated by a dielectric liquid and subjected to an electric voltage.
 Herald Projector

The blades are made up of Titanium and cost around 45000 INR to 50000 INR.

The damaged parts are sent for re-work.

Then, Non-destructive testing is carried out with corrosion prevention.

Organic lubricants are used; and oil is used a s a masking agent.

ETCHING, also known as chemical milling, takes place after the lubricant dissolves in the solvent.
After two washes in water, it is dipped in nitric acid and then in hot water at 70℃. This prevents
corrosion.

Vegetable dies are used as fluorescent penetrants to observe micro cracks, also known as hairline
cracks, that are not visible with the naked eye.

Red dye is no longer used as it causes ozone depletion.

 SHAPE MEMORY
The original shape retains after deformation.

The temperature at which the material returns to its original shape is called the TRANSFORMTION
TEMPERATURE.
Steel is added to reduce the Transformation temperature.

PROCEDURE
 The alloy is made up of 50% Titanium cut pieces, 47% Nickel pellets and 3% Iron pieces.
 All The pieces are subjected to vacuum induction to form an alloy.
 This is further fed into a vacuum under the influence of an arc resistance to form a VAR ingot.
 This is further forged into a block.
 The block is rolled to form a plate.
 The plate is drawn into thin wires.
 Finally, the SMA rings are formed.
The SMA conduit pipe assembly is used to avoid electric surge and direct the lightning away from the
aircraft fuel tanks during thunderstorms.
The pipe is fitted with an insulating material made up of PEEK (Poly Ether Ether Ketone) by means of SMA
rings at the junction of insulator and metal pipe in order to avoid leak of fuel.
These rings can withstand a load of 700 pounds.

The various machines used for these processes are-

o VIM machine
o VAR machine
o Ring Rolling Machine
o 3-D printing machine for sand moulds.
DEVELOPMENT

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.
All the paper work including Manufacturing processes and technical drawings are issued from the
development Department.
All the technical details are received from the customer.

Development Batch: Batches are manufactured prior to full scale Production batches, used to fine-tune
processes before committing to full scale manufacture. It’s a Test batch for checking material Quality. This
batch is ordered by the customer to see the final product to proceed with the production batch.

This department decides all the process required for manufacturing of the product by using CAD and
Simulation software.
Simulation Software
 DeForm: - Forging
 ProCast: - Casting
 CAD Software
 Unigraphics
 Solidworks
 AutoCAD
Raw material procurement is done as per company policies and restrictions.
CMPL LAB (Central Materials Processing Lab)

INORGANIC LAB-
 Alloys and raw materials used for casting and forging are tested here.
 Liquid samples are tested using wet Analysis.
 Volumetric and gyrometric titrations are done using burette titrations.
 Taber Abraser machine is used to detect wear and tear.
 Breakdown voltage Tester is used to check breakdown voltage.
 Microwave Digestor is used to dissolve alkali and acid for the metal.
 Coating Thickness Tester is used for protection.
 UV visible Spectrometer used for magnesium component wear and tear detection.
 AUTOTITRATOR is used for automatic acid titration.
 KARL FISCHER TITRATOR is used to calculate moisture content in quenching oil.
 PH meter
 CONDUCTIVITY METER.
 SALT SPRAY TEST CABINET- creates a false sea shore atmosphere to calculate maximum
corrosion rate.

ORGANIC LAB-
 Rubbers, adhesives, sealants, composites, paints etc. are tested. (Non-metallic in nature).
 FOL (Fuels, Oils, and Lubricants are also tested.)
 PTFE (TEFLON)-
o Acrylic Plastic (bulletproof canopies)
o Silicone rubber
o Viton Rubber
o Neoprene Rubber
o PTFE (Poly tetra fluoro ethylene)

 Universal Testing Machine (UTM) – to test tensile strength of rubber.

 Hardness Testing Machine – to check certain characteristics of rubber like hardness, elongation,
strength and stickiness.
 Densitometer – to check density (Archimedes Principle)
 Scratch Hardness Tester – painted panels
 Impact Tester – to check the hardness of the paint so that it doesn’t peel off and expose the metal to
corrosive environment.

PAINT AND ADHESIVE TESTING
 Saybolt Universal Seconds Viscometer
 Pensky Marten’s Closed cup apparatus
 Grease Penetration Tester
 Cleveland Open Cup apparatus

OVEN ROOM
Sealant rubber is subjected to temperature after a hydraulic fluid dip.
Difference in weight indicates volume change
METALLURGY LAB
Microscopes used are-
1. Leica make inverted optical microscope. (50 X- 1000X)
2. Brindl Test – Universal hardness
3. Buehler Micromet microhardness Tester
 Fine grain elements are preferred for better strength.
 Heat treatment is given to larger particles to make them finer.
 Chip analysis is also carried out.

MECHANICAL LAB
 Instron Universal Test Machine- capacity is 100 kN.
 EXTENSOMETER is used to determine yield point.
 CREEP occurs at high temperature and less load. It usually occurs in the compression chamber.
 STRESS RUPTURE occurs when the metal breaks at breaking point.
 BLADES possess both creep and stress rupture.
 TENSILE test occurs for Nickel alloys and Titanium alloys at 650℃ and 550℃ respectively.
 IMPACT test.

X-RAY LAB
Non-destructive testing is carried out by X-ray testing.
A SCRATCH test is done on the casting since some cracks can’t be seen by the naked eye.

This porosity is found when there are small voids, holes or pockets of air that is found within metal.
Typically, this porosity occurs when air is trapped into the metal by the die casting machinery, often
leaving gaps at the top of the die or filling a mould too slowly and having some solidification occur too soon.
QUALITY CONTROL

Quality Control staff members have many responsibilities, but everything they do contributes to the quality
of the end product, which is the main objective of quality control. This task, however, is not a simple one,
because it entails an incredible number of inspections, checks and reviews before a product can be offered
for sale.

Every person involved in making a product is responsible for making it a quality product. Quality
departments, such as Quality Control (QC) or Quality Assurance (QA) cannot inspect quality into the
product. The Quality Departments exist as an audit function within the manufacturing and packaging areas.

 Approve or reject all procedures, specifications, methods, and results

 Approve or reject all raw materials, packaging materials, labelling and finished products
 Review all production records for accuracy and completeness before approving for distribution
 Establish procedures for revising procedures, formulas, and more
 Approve changes to procedures, formulas, and more
 Ensure that the latest revision is being used at all times
 Perform all the required tests to ensure identity, purity, potency and composition, and to ensure that
products are not contaminated or adulterated.