INTERNSHIP REPORT

ABSTRACT

The world of metallurgical and materials engineering is not only limited to

steel and blast furnaces, but there is much more interesting factory work involved,
which is seen here at the Foundry & Forge division. Casting and Forging seems
to be an easy job, but prone to defects that cannot be identified by the naked eye,
or while conducting the process. Whether it is investment casting, or be it in any
foundry, say the magnesium foundry or the non-ferrous foundry, pouring defects,
cracks, inclusion, etc., are bound to take place. However, on our part, we can
only, take certain precautions to prevent these defects from taking place. As
students, it is our duty, to learn anything new and interesting, which we were not
aware of before. This internship report, as a whole, aims at providing an insight
into the working of the various factories at the Foundry & Forge Division of HAL
Bangalore complex.

Page | 1
 INTERNSHIP REPORT

INDEX

1) Introduction
2) Furnace
3) Powder metallurgy shop & Ferrous shop
4) General Forge
5) Ring Rolling shop
6) Shape Memory Alloy shop
7) Precision forge shop
8) CMPL-Central Material & Processes Laboratory
9) Non-Ferrous & Magnesium Foundry
10) Precision Foundry
11) Die shop
12) Rubber shop
13) Development Shop
14) Conclusion

Page | 2
 INTERNSHIP REPORT

INTRODUCTION
ABOUT THE ORGANISATION:

Hindustan aeronautics limited (HAL) is an Indian state-owned aerospace and

defence company headquartered 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 spare
parts. It has several facilities spread across India including Nasik, Korwa,
Koraput, Lucknow, Bangalore and Hyderabad. HAL HF-24 Marut fighter-
bomber was the first fighter aircraft made in India.

Currently this company manufactures the LCA Tejas (Light combat Aircraft),
ALH Dhruv (Advanced Light Helicopter), Cheetah, Chetak, Sukhoi Su30Mkll,
LCH (Light Combat Helicopter), besides others. It also conducts overhaul of
various aircrafts such as the Mirage 2000 and the Jaguar.

HAL Bangalore has many division such as the Aircraft Division, the Foundry &
Forging Division, the Helicopter Division, and the Overhaul Division, besides
others. I have interned at the Foundry & Forge Division, and hence I will speak
in detail about this Division only.

FOUNDRY & FORGING DIVISION:

THE Foundry & forging Division is composed entirely of metallurgical and

mechanical engineers. They manufacture all the major aeronautical parts and
spare parts the year round, so that the Indian air Force and its varied customers
never fall behind. Infact the relationship of HAL & Rolls-Royce Aerospace has

Page | 3
 INTERNSHIP REPORT

crossed over 50 years. This division major international customers are Boeing,
Airbus, General Electrical, Rolls-Royce, Adour, etc.,

The Foundry & Forge Division was established in 1374. The Division’s facility,
set up on a lush expanse of 32 acres, manufactures castings, Forgings, Rolled
Rings, Shape Memory Alloy Ferrules, Brake pads and Rubber products for
critical applications for the Aeronautics, Space, Defence, Locomotives, 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 application in war and peace, meeting the exacting needs of
every customer.

FACTORIES AND OFFICES IN F&F Division:

The factories & Offices in the Foundry & Forge Division can be listed as follows:

 Powder Metallurgy shop

 Ferrous Foundry
 Non- Ferrous Foundry
 Pattern shop
 Rubber shop
 Ring rolling
 Magnesium Foundry
 Precision Foundry
 General Foundry
 Die shop
 Machine shop
 Precision forge
 Shape memory
 Development department
Page | 4
 INTERNSHIP REPORT

 Quality control & Stores

 Central Materials Processing Laboratory (CMPL)
 Investment Casting

SERVICE SPECTRUM:

The mission of Foundry & Forge Division is to deliver Competitive products and
services that meet or exceed our customers’ expectations. They shall achieve our
mission by:

 Understanding customers need.

 Developing their human resources.
 Using systematic selection, develop technical support and surveillance of
their suppliers and sub-contractors.
 Improving regularly the facilities.
 Continuously improving manufacturing methods.
 Introducing products improvement based on customer feedback.

MISSION OF F&F Division:

HAL, as a responsible PSU, strives to accomplish the vision of becoming a

significant global player in the aerospace Industry and at the same time is focused
on environment protection, conservation of natural resources, welfare of
employees and the society at large. HAL has been demonstrating its sense of
responsibility towards both the community and the environment through various
initiative over the years, proactively nurturing community growth and
development. Several initiatives and measure have been undertaken over the past
few years to reduce the impact of HAL’s operations on environment.

Page | 5
 INTERNSHIP REPORT

FURNANCE
DEFINITION:
A Furnace is an equipment used to melts metals for casting or to heat materials
to change their shape (e.g. rolling, forging) or properties.

ELECTRICAL FURNANCE

An electrical furnace is similar to a conventional gas forced air furnace

except that it produces heat with electrical heating elements instead of
gas burners. Circuit breakers that control the heating elements may be either
inside or outside the cabinet.

TYPES OF ELECTRICAL FURNANCE

 Gas fired furnace
 Oil fired furnace
 Induction furnace
 Open hearth furnace
 Pit type gas carburizing furnace
 Vacuum induction furnace
 Arc remelting furnace
 Pressure centring furnace
 Electrically heating furnace
 Vacuum heat treatment furnace etc…...

Page | 6
 INTERNSHIP REPORT

VACUUM INDUCTION MELTING

A VIM furnace is simply a melting crucible inside a steel shell that is connected
to a high-speed vacuum system.

The heart of the furnace is crucible with heating and cooling coils and refractory
lining. Heating is done by electric current that passes through a set of induction
coils. The coils are made from copper tubing that is cooled by water flowing
through the tubing. The passage of current through the coils creates a
magnetic field that induces a current in the charge inside refractory. When
the heating of the charge material is sufficient that the charge has become all
molten ,these magnetic field cause stirring of the liquid charge. The optimal
induction coils frequency for heating depends on the charge shape, size and
melt states.

Page | 7
 INTERNSHIP REPORT

HIGH TEMPERATURE VACUUM

SINTERING FURNACE

This furnace are equipped with electrical resistance heating or with induction
heating. They can be used for numerous purposes because they apply vacuum
as well as inert atmosphere of ceramics or powder metallurgical parts.

They are also used for different high-temperature process

Such as carburization, recrystallization, silicon, infiltration,
Nitration (formation of si3n4) vacuum sintering or metallization.
Available volume : 1 dm³ to 10 m³ at max.
Temperature : 2800°c

Page | 8
 INTERNSHIP REPORT

ELECTRIC HEATING FURNACE

Electric heaters are usually 100% efficient at converting the electricity into heat
in the room where they are located. An electric furnace heats air moved by its
fan over several electric resistance heating elements. Electric heaters have more
than one elements of 3.5 to 7kw each that works like the elements in a toaster.
The 24-volt thermostat circuit energizes devices called sequencers that bring
the 24-volts heating element on in stages when the thermostat calls for heat.
The multiple speed of switches to a higher speed as more elements engage to
keep the air temperature stable.

Page | 9
 INTERNSHIP REPORT

OPEN HEARTH FURNACE

Open hearth furnace is one a number of kinds of furnace where excess carbon
and other impurities are burnt out of pig-iron to produce steel. Since steel
is difficult to manufacture due to its high melting points. Normal fuels and
furnace were insufficient and the open hearth furnace was developed to
overcome this difficulty. Compared to Bessemer steel, which is displaced
its main advantages were that it did not expose the steel to excessive nitrogen
(which would cause the steel to become brittle) was easier to control and it
permitted the melting and refining of large amounts of scrap iron and steel.

Page | 10
 INTERNSHIP REPORT

CUPOLA FURNACE
A cupola or cupola furnace is a melting device used in foundries that can be used
to melt cast iron, Ni-resist iron and some bronzes. The cupola can be made
almost any practical size, the size of a cupola is expressed in diameters and can
range from 1.5 to 13 feet (0.5 to 4.0 m). [1] The overall shape is cylindrical
and the equipment is arranged vertically, usually supported by four legs,
the overall look is similar to a large smokestack.

The bottom of the cylinder is fitted with doors which swing down and out to
'drop bottom', the top where gases escape can be open or fitted with a cap to
prevent rain from entering the cupola. To control emissions a cupola may
be fitted with a cap that is designed to pull the gases into a device to cool the
gases and remove particulate matter.

Page | 11
 INTERNSHIP REPORT

Pit type gas carburizing furnace

Carburizing or carburization is a heat treatment process in
which iron or steel absorbs carbon while the metal is heated in the presence of a
carbon-bearing material, such as charcoal or carbon monoxide. The intent is to
make the metal harder. Depending on the amount of time and temperature, the
affected area can vary in carbon content. Longer carburizing times and higher
temperatures typically increase the depth of carbon diffusion. When the iron or
steel is cooled rapidly by quenching, the higher carbon content on the outer
surface becomes hard due to the transformation from austenite to marten site,
while the core remains soft and tough as
a ferrites and/or pearlite microstructure.

Working

The process of carburization works via the diffusion of carbon atoms into the
surface layers of a metal. As metals are made up of atoms bound tightly into a
metallic crystalline lattice, the carbon atoms diffuse into the crystal structure of
the metal and either remain in solution (dissolved within the metal crystalline
matrix — this normally occurs at lower temperatures) or react with elements in

Page | 12
 INTERNSHIP REPORT

the host metal to form carbides (normally at higher temperatures, due to the
higher mobility of the host metal's atoms). If the carbon remains in solid
solution, the steel is then heat treated to harden it. Both of these mechanisms
strengthen the surface of the metal, the former by forming pearlite or marten
site, and the latter via the formation of carbides. Both of these materials are hard
and resist abrasion.
Gas carburizing is normally carried out at a temperature within the range of 900
to 950 °C.
In oxy-acetylene welding, a carburizing flame is one with little oxygen, which
produces a sooty, lower-temperature flame. It is often used to anneal metal,
making it more malleable and flexible during the welding process.
A main goal when producing carburized work pieces is to ensure maximum
contact between the work piece surface and the carbon-rich elements. In gas and
liquid carburizing, the work pieces are often supported in mesh baskets or
suspended by wire. In pack carburizing, the work piece and carbon are enclosed
in a container to ensure that contact is maintained over as much surface area as
possible. Pack carburizing containers are usually made of carbon steel coated
with aluminum or heat-resisting nickel-chromium alloy and sealed at all
openings with fire clay.
Hardening agents
There are different types of elements or materials that can be used to perform
this process, but these mainly consist of high carbon content material. A few
typical hardening agents include carbon monoxide gas (CO), sodium
cyanide and barium carbonate, or hardwood charcoal. In gas carburizing, the
CO is given off by propane or natural gas. In liquid carburizing, the CO is
derived from a molten salt composed mainly of sodium cyanide (NaCN) and
barium chloride (BaCl2). In pack carburizing, carbon monoxide is given off by
coke or hardwood charcoal.
Page | 13
 INTERNSHIP REPORT

Dimensional changes
It is virtually impossible to have a work piece undergo carburization without
having some dimensional changes. The amount of these changes varies based
on the type of material that is used, the carburizing process that the material
undergoes and the original size and shape of the work piece. However, changes
are small compared to heat-treating operations.
KANTHAL GLOBAR SIC HEATING ELEMENTS

Change in material properties:

Work material properties Effects of carburizing

 Increased surface hardness
Mechanical  Increased wear resistance
 Increased fatigue/tensile strengths
 Grain growth may occur
Physical
 Change in volume may occur
Chemical  Increased surface carbon content

Silicon carbide (SiC) electric heating elements for element temperatures

up to 1625°C (2927°F), available in a wide variety of standard sizes and
geometries, or in customized designs to meet the specific needs of various
processes and equipment.

Page | 14
 INTERNSHIP REPORT

Why Vacuum heat treatment furnace are important to aerospace

Vacuum heat treating furnace are used for a range of applications. However,
one of the most important uses is for the heat treatment of Alluminum alloys
used in aircraft structures. While the type of alloy an aircraft chooses is
important, when it comes to aircraft design, the heat treatment used on that
metal is just as crucial.

For obvious reasons, aircrafts need to function at optimum levels and

environmental conditions have everything to do it with strength and life of a
plane. A planes life is dependent on the grain structure of its alloy which in turn,
is totally dependent on vacuum heat treating.

A vacuum heat treating furnace used to heat metals to extremely high

temperatures through high consistency and low contamination of gases. The
vacuum blocks oxygen which reduces the rapid oxidation. Vacuum heat furnace
improve the overall condition of the metal alloy in that they cover the area more
evenly, make the cooling process quicker, and improving the overall life and
functionality of the metals.

Page | 15
 INTERNSHIP REPORT

Electrical substation

Fig (a). Indoor substation fig (b). outdoor substation

Electrical substations are the interface between parts of the distribution

systems and transmission systems. These fenced off areas step down
the voltage in the transmission lines to one that is suitable for the distribution
system. They are also equipped with circuit breakers to protect the distribution
system, and can be used to control the flow of current in various
directions.[2][3] They also smooth and filter voltage fluctuations caused by, for
example, an increased load.

Components:
Transformers lower the very high transmission voltages into a voltage less than
10 000 volts, which is suitable for distribution systems. Substations are also
often equipped with a bus that splits off the current in multiple directions, as
well as circuit breakers and switches which will allow the isolation and direct
control of certain parts of the transmission and distribution systems.[2] Many
substations also include capacitors to smooth the voltage output.

Page | 16
 INTERNSHIP REPORT

Powder metallurgy shop and Ferrous shop:

Fig: Schematic process of Powder Metallurgy

Fig: Hot liquid Iron being poured into mould

The Powder Metallurgy Shop of the division manufactures a range of sintered

friction and anti-friction materials such as Copper and Iron-based brake pads and
bimetallic anti friction bushes for aircraft. The unit has capability to design,

Page | 17
 INTERNSHIP REPORT

development, manufacture and testing of military and Civilian Aircraft brake

pads which have been approved by the DGAQA (The Directorate General of
Aeronautical Quality Assurance) and CEMILAC.

Manufacturing Facilities:

 Mixing of friction material powder formulation in a double cone blender

 Compaction of friction material powder compacts in 250T press.
 Hydrogen pusher furnace for powder reduction & bulk sintering
 Loading of charge boats in pusher furnace for loose sintering
 Stacking of green friction compacts and backing frames for pressure
sintering
 Pressure sintering in progress
 Heating hood of furnace lifted after sintering

Testing Facility for Powder Metallurgy items:

 2-PAD Lab Scale Dynamometer Testing

 Optical microscopy and image analysis
 Instrumental chemical analysis
 Hardness testing
 Ultrasonic bond quality testing
 LEO 440i SEM Analysis
 Bend Testing for adhesion of friction material with supporting plate

Page | 18
 INTERNSHIP REPORT

General Forge:

Fig: Hot metal ingot being loaded into a hammer forge

The General Forge shop manufactures forgings such as open forgings, closed die
forgings and material forged rings made of a variety of alloys. It also consists of
a heat treatment section with furnaces for hardening, tempering, solution zing,
ageing, normalizing and annealing with temperature controllers and recorders,
and a process and fettling shop.

Forging can produce a piece that is stronger than an equivalent cast or machined
part. As the metal is shaped during the forging process, its internal grain texture
deforms to follow the general shape of the part. As a result, the texture variation
is continuous throughout the part, giving rise to a piece with improved strength
characteristic.

Page | 19
 INTERNSHIP REPORT

Infrastructure Facility:

 3000 ton Hydraulic press with stand alone die heating furnace
 10 ton counter blow hammer with four 500 ton cupping press , a one ton
drop gravity hammer and pneumatic hammer of 1500kg , 1000kg,
500kg,150kg capacity
 Cutting machine such as vertical and horizontal band saw , cold circular
saw, electric discharge saw, abrasive cutting unit
 Battery of electrical resistance heated furnace with temperature regulatory
devices
 Heat treatment section with furnaces for hardening ,tempering ,solution
zing
 Shot blasting machine
 Full fledge process and fitting shops

Capabilities:

 A range of press up to 3000 ton capacities and process shop for NDT
 Die shop for manufacturing of dies with CNC facilities, copy milling and
EDMS
 General forgings for aerospace and commercial applications in Al, Ti
alloys, steels and nickel based super alloys.

Forging Facilities:

Pneumatic hammers of 1500, 1000,500 and 10 kg are available. These are Open
Die Power Forging hammers and use pneumatics to drive the hammer. These are
used for closed and open die forging wherein the hammer strikes a work piece
which is placed on a die of required shape and rains blows on it create an
impression of the die. For example, the BANNING 1000 kg hammer gives 100

Page | 20
 INTERNSHIP REPORT

blows per minute and the BANNING 1500 kg hammer gives 85 blows per minute
to the work piece.

Gravity Drop Hammers of 1 tonne capability are used. These are similar to the
pneumatic hammers as far as end product is concerned but here gravity is utilized
to drop the hammer, hence the name.

BECHE Counter Blow Hammer of 10 tonne capability is used wherein both the
hammer and the anvil move together and the work piece is compressed in between
them.

Clipping Press of 500 tonne capability which is used for trimming of the
unwanted portions of forgings and can also be used to create holes in the work
piece. A punch will force the work piece through a die with a sharp edge for the
purpose of trimming. Clippings are returned for recycling.

Water Hydraulic Press of 3000 tonne capability is used for press forging, which
works by applying a continuous pressure or force on the workpiece.It is also used
for upset forging, which increases the diameter of the work piece by compressing
its length.

Cutting machines such as vertical and horizontal band saws, cold circular saws
and abrasive cutting unit are also available for cutting the metal billets.

Page | 21
 INTERNSHIP REPORT

Heat treatment facilities:

Various furnaces are available for use in the heat treatment section. Most of these
are NADCAP approved and assigned various classes, based on the temperature
tolerance range. The temperature tolerance range is the temperature above or
below the operating temperature of the furnace, which can be tolerated by the
furnace.

There are 5 classes:

 Class 1 (± 3°C)
 Class 2 (± 5°C)
 Class 3 (± 8°C)
 Class 4 (± 10°C)
 Class 5 (± 15°C)

Some of the furnaces:

 GH-10 Furnace is a Class 4 and Class 5 furnace with an operating

temperature of 6501180°C.It is used for the process of annealing
 GH-4 Furnace is a Class 1 and Class 2 furnace, with lower operating
temperature than GH-10 furnace. It is an air circulation type furnace, where
a fan is used to circulate air and uniformly distribute heat within the
furnace. This furnace is used for tempering.
 GH-5 Furnace is a Class 2 furnace with operating temperature of 150-
680°C .It is a type D instrument, which means that it consists of 1 Main
Controller and 1 Recorder for the furnace. This furnace is also used for
tempering.
 GH-7 Furnace is a Class 3 and Class 4 furnace and can be used for
normalizing, tempering and hardening.

Page | 22
 INTERNSHIP REPORT

 GH-3 Furnace is a Class 1 and Class 2 furnace with rather low operating
temperature of 100-350°C.

Product range:-

Blocker Forgings:
Tolerance in Surfac finis
Material Size in mm mm e h Weight(kg)
(µm)
Al alloy 800*250*100 ±5 50 10-15
Ti alloy (Dia)250 * 50 ±5 12 10-15
Ni based alloy (Dia)250 * 50 ±5 22 10-15
Steels 300*175*150 ±5 65 15-20

Closed die forgings:

Tolerance
Material Size in mm (mm) Surface Weight(kg)
finish(µm)
Al alloy 650*200*175 +2/ -1 50 3-5
Ti alloy 300*150*150 +2 / -3 11 3-5
Ni based alloy 300*100*150 +3/-1 14 6-8
Steel 600*175*150 +3/-1 65 6-8

Page | 23
 INTERNSHIP REPORT

Ring Rolling shop:

Manufacturing steps involved in the ring rolling shop is as follows:

 Cutting the steel or titanium bars into required length of specified

diameter. Small diameter rod will be the forged structure. Big
diameter rod will be the casted structure.
 Rod is heated in the high temperature furnace (900 C – 11 0 C). Those
are electrically heated furnace (slowly it raises the temperature –
limitation, hence LPG suits mostly).
 Pressing is done by hydraulic press (1500 ton).
 Piercing which is nothing but making hole in that circular objects. Tool
steel is used for punching hole whose wear resistance is high.
 These are again kept for heating in the furnace under proper soaking
period (uniform distribution of the heat). Over soaking leads to grain
growth.
 After heating, they are hot rolled in the ring rolling mill.

Page | 24
 INTERNSHIP REPORT

 Ring rolling mill consists of mandrel, main ring, centring roll, two axial
rods. - Centring rod has sensors which gives feedback. - Axial rods control
the thickness of the rod. - The rod is compressed between the mandrel and
main ring. - The rod will expands more in radial direction.
 During heated, there may be some bending hence they are pressed under
hydraulic press.
 After rolling, they are heat treated to improve the properties and then
machined.
 Small rings are used in aircraft engines.
 Larger rings are used as bearings in helicopter and in transmission parts,
battle tanks, and satellite launch vehicles.
 In helicopter mostly titanium, nickel and steel rings are used.
 Ti6Al4 alloy is mostly used in aerospace. This can easily forge.
 Ti6Zr3 alloys are difficult to forge.

Infrastructure:

 Computer controlled ring rolling mill with 100 ton radial force and 63
ton axial force
 Battery of electrically heated low and high temperature (up to 2.2m
length) with temperature controllers & recorders.
 Quenching operation after rolling wherever applicable
 A 800 ton capacity ring expander
 A 1500 ton upsetting press
 Handling aids such as manipulators and EOT cranes for heavy
products
 Raw materials cutting facility( up to 400 mm square section ) in all
alloys

Page | 25
 INTERNSHIP REPORT

 Bottom drop quench furnace for heat treatment of Al alloy rings (up
to 3.5m diameter)

Capabilities:

Plain and profiled rings in Al alloys, Ti alloys and Ni based super alloys up to
2.5m diameter. In house facilities for pre & post rolling operations such as
cheesing, heat treatment, ring expansion / compression, NDT and machining.
Product range:

Material Size range in mm Maximum weight (kg) Finish

Al alloys O.D (300- 400 Machine finish
2500),I.D(200-
2000),thickness(30-
250)
Carbon & alloy
steels O.D (300- 1300 Machine finish
2500),I.D(200-
2000),thickness(30-
250)
Ti alloys O.D (300- 350 Machine finish
2500),I.D(200-
2000),thickness(30-
250)
Maraging/
stainless O.D (300- 650 Machine finish
steels &
Nimonics 2500),I.D(200-
2000),thickness(30-
250)

Page | 26
 INTERNSHIP REPORT

Shape Memory Alloy Shop:

This shop produces the shape memory alloy material for aircraft application.
 These alloys have unique property of remembering their original shape.

 Shape change take place when deformed but revert back to their original
shape when they cross a transformation temperature.
 These shop facilities for manufacturing of SMA rings for aerospace
application.

 These are the alloys of Titanium and Nickel. Input to VIM is Ni pellets, Fe
and Ti cut pieces.

 These are melted under VIM and purified using VAR then the
transformation temperature is got using DSC. Thereafter it is subjected to
thermo mechanical treatment like forging, hot rolling, and heat treatment
to obtain ferrules.

 SMA rings (ferrules) used in LCA (light combat aircraft) have

transformation temperature of -55deg Celsius.

 LCA uses a total of 172 number of SMA ferrule rings in 5 different size
varying diameter from 20-50 mm for clamping PEEK (poly-ether ether
ketone) insulator tubes into aluminium tubing which carry the fuels.

5.0 Infrastructure:

 Vacuum Induction melting furnace (VIM) - 50kgs capacity. The crucible

used in here is coated with yttrium oxide paint to avoid the reaction
between nickel and graphite crucible. Vacuum pressure of 0.005 Pa is be
used.
 Vacuum arc re-melting (VAR)- up to 150mm diameter
 DSC- differential scanning calorimeter
 SEM- scanning electron microscope
 Universal testing machine for testing strength
 Sand storing silos of capacity 1200kg

Page | 27
 INTERNSHIP REPORT

Precision forge shop:

Introduction:

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. The shop produces near net
forgings.

Infrastructure:

 Friction screw presses of 3200 ton, 2000 ton, 500 ton and 300 ton capacity.
 1000 ton direct drive presses.
 250 ton horizontal up-setter.
 1.5 meters rotary hearth furnace.
 Low and high temperature box type furnace.
 45 and 70 ton trimming presses.
 Abrasive blasting equipment.

Page | 28
 INTERNSHIP REPORT

 Vibratory finishing mills.

 Process shop for degreasing, etching, electro polishing and size-etching
operations.
 Fluorescent penetrant inspection unit.
 Double-ended polishing lathes.
 Dedicated inspection facility including CMM for precision forged blades.

Capabilities:

 Precision net shape aero engine compressors and turbine blades in

aluminum alloys, titanium alloys, steel and nickel based super alloys.
 Precision near net forgings for commercial and export orders.

 CAD/CAM/CMM software route of design, manufacture and inspection

for both component and tooling using latest software’s.

Description of the shop:

 The shop manufactures parts required for aircrafts such as rotor blades,
stator blades etc., of size varying from moderate to small which are near
net forged so as to reduce the extent of post machining.

 The products are made from steels, titanium alloys, nickel base alloys and
aluminium alloys.
 The forging temperature range for different alloys are given below,
o Steels – 1050 C -1150 C

o Titanium alloys – 940 C – 980 C

o Aluminium alloys- 400C-500C

 The raw materials for this are either small billets or pre-forged materials
which are forged at high temperatures.
 The forging is done along the grain flow direction. The parts are then sent
to fettling section where the excess or the unwanted parts are removed and
surface finishing is done. Hot blast is done to remove scales formed.

Page | 29
 INTERNSHIP REPORT

 Then the products are sent to final inspection unit to check whether surface
and internal defects are present and then they are passed for the service.
 Different processes to detect defects are done.
Some of them are listed below:

 The products are degreased i.e. vapour degreasing or alkaline degreasing

and then etching and electro polishing is done.
 Caustic etching is done for aluminium alloys, acid pickling for steel,
glass coating for titanium alloys to avoid hydrogen pickup at high
temperature. Anodizing bath with temperature of 38C-40C & 30-100
gm./Lt chromic, De smut – (HNO3 –380-400 gm/Lt + HF – 1.5-2.5
gm/Lt), DM bath (distilled mineral bath), neutralization – Na2CO3 - 40-
60gm/Lt,

Product range: Aero engine blades

Surface
Material Size in mm Tolerance (mm) finish Weight(kg)
(µm)
Aluminium 400*200*5 +0.25|-0.00 <1 0.15
Ni based super 95*38*5 +0.15|-0.00 2.5-3.0 0.11
alloys
Stainless steel 150*50*5 +0.30|-0.00 <1 0.30
Titanium alloys 250*100*5 +0.30|-0.00 <1 0.30

Page | 30
 INTERNSHIP REPORT

CMPL-Central materials and processes laboratory

 Chemical inorganic section
 Chemical organic section
 Calibration section
 NDT section
 Metallurgy section
 Mechanical testing section and workshop
 Learning centre and documentation unit

Functions of central materials and processes laboratory:-

Chemical, metallurgical and mechanical testing of

Testing and quality control raw
Materials, in-process and finished products.

Calibration Force measuring equipment and pyro-metry.

Technical investigation Service and process failure investigation

 Training & certificate

NDT (Non-Destructive Test)
Research and development
Learning centre
 NDT consultancy techniques &
documentation
 Materials development, design and data
generation
 Development of special processes and
products
Training, documentation and library service.

Page | 31
 INTERNSHIP REPORT

 Mechanical testing section:

Some of the facilities:

 Servo hydraulic UTM-100kN Dartec

 Servo hydraulic UTM-100kN Zwick
 UTM -25kN TIRA
 UTM-25kN INSTRON
 Avery tensile testing machine-450kN
 Creep and stress rupture test machine- SATEC,INSTRON & GLOHEAT
 Charpy & Izod impact testing –FTM, Avery& FIE make
 Rotating bending fatigue test machine (RT)
 Stress corrosion cracking test machine –Alternate and constant immersion
 Elevated temperature rotating beam fatigue testing machine.
 Calibration section:
Service offered:
 Calibration of all type of thermocouples (15C-1100C)
 Onsite calibration/temperatures uniformity survey of furnaces
 Calibration of weighing balances.
 Calibration of cable tensiometers, mechanical force gauge, Vickers
hardness testing machine, Rockwell hardness testing machine, Brinell hardness
testing machine.
Facilities:
 Tubular thermocouple calibrating furnace (0c-1200C)
 Isotech and fluke portable thermocouple calibrating furnaces (150C-
1000C)
 Fluke 525/A temperatures/pressure calibrator
 Isotech quick calculation low temperature thermocouple calibrating
furnaces (-15C-140C)

Page | 32
 INTERNSHIP REPORT

 Fluke R type reference thermocouple with built in junction

 Microtech torque wrench tester 0.55kgfm
 Research and development:
CMPL provides technical data, testing and analytical service for:

Metallic, Non-metallic and engineering materials

Development and manufacture of metalloceramic and phenolic composite

friction materials for high energy brakes.

Development and manufacture of large and complex casting of Al, Mg, Cu base
alloy , cast iron , special high performance metals and alloys.

Development of aero engine compressor blades and other general and precision
forgings in high strength Al alloy, Steels, Ti, Ni based super alloy.

Identify the root cause of failures and recommend remedial measures to prevent
recurrence of such failures.

Services:

 Radiographic inspection of casting, welding’s, assembled components

 Electrical conductivity check by eddy current method
 Ultrasonic and eddy current inspection
 Magnetic particle inspection
 Penetrant test.
 Chemical section:
Facilities:

 Atomic absorption spectrometer GBC

 Direct reading optical emission
 Spectrometer BAIRD 1000-DVA
 UV-Visible spectrophotometer systronics
Page | 33
 INTERNSHIP REPORT

 Hydrogen determinator LECO RH 404

 Carbon/sulphur determinator LECO CS 200
 Salt spray test cabinet-ASCOH 455t
 Taber abrasive apparatus
 Karl-Fischer titrator –Metrom
 Conductivity & PH meter-Metrom
 Flame photometer
 Breakdown voltage tester Zeal ZSHV SAV
 Coating thickness tester (Dual scope MP40)
 PTC digital durometer
 Saybolts universal seconds viscometer
 Brookefieldsynchro electric viscometer
 Micro hardness tester
 Microwave accelerated reaction system MARS5
Service:

 Analysis of chemical compound by instrument/wet analysis

 Analysis of plating & surface treatment solution for process consistency
 Salt spray test – accelerated corrosion resistance test
 Chemical analysis support in characterization of metalloceramic and
phenolic composite friction materials for brake pads
 Testing of adhesives, sealants, oils, fuels, paints, rubber, plastics.
 Metallurgical section:
Facilities:

 Nikon (Inverted), Leitz(upright) optical microscope

 Automatic image analyzer
 Stereo binoculars microscope

Page | 34
 INTERNSHIP REPORT

 SEM with EDAX

 Ferrite meter
 Automatic sample polisher
 Portable hardness tester
 Beuhlumicrohardness tester
 Indented universal hardness tester
Service:

 Macro structural analysis & macro etching of ferrous and non-ferrous

materials
 Micro structural analysis of metals & alloys by metallographic techniques
 Estimation of grain size by microscopic method
 Determination of non-metallic inclusion rating, graphite flake size, type
and distribution in cast iron
 Pre examination of metalloceramic brake pads
 Depth of decarburization of steels
 Micro and macro hardness of metals and alloys.
 Case depth measurement in low carbon steel by micro scoping and
hardness test
 Measurement of cavities and plating thickness by microscopy
 Investigation of accident or incident of aircraft & general engineering
components.

Page | 35
 INTERNSHIP REPORT

Non-Ferrous shop (Aluminium foundry) and

Magnesium Foundry:
Introduction: The non-ferrous foundry produces aluminium alloys for aircraft
applications. The foundry produces lightweight Al-Si and Al-Cu alloys. There
are oil fired and gas fired furnaces to produce molten metal, an automated system
to produces sand moulds, and a fettling section for removal of excess metal from
the cast parts

Because of its lightweight nature, magnesium and its alloys are preferred
for usage in aircraft. The magnesium foundry thus produces high grade
magnesium alloy castings.

Both these foundries have sections for mold making, melting and
pouring, and fettling sections.

Page | 36
 INTERNSHIP REPORT

Mould section

The mould section at the foundry produces sand moulds in an automated

fashion. The process of mould making is described: The filtered beach sand is
mixed well with a binder, accelerator and catalyst, and fed into either an 8 ton or
25 ton capacity Wesman binding machine.

The mixed sand is loaded and compacted onto a mould box containing the
pattern for the casting. This mould box is rotated 180oin the vertical direction to
separate the pattern from the mould. The other half of the mould is also made in
the same fashion, and the operation repeats in a continuous fashion. Meanwhile,
the cores required are made by filling sand and binder into core boxes. These
cores, along with the chaplets, ceramic filters etc. are assembled on another
conveyor belt, to obtain moulds which are ready for the liquid metal.

Melting section

The melting section is where preparation of the required alloys takes place.
Oil fired and gas fired furnaces are used.

Aluminium has a tendency to dissolve gases, a rotary degasser is used is

used to minimize the dissolution of gases in the melt, and maximize the removal
of any such dissolved gases. Air or nitrogen is used for purging the dissolved
gases.

Magnesium, on the other hand is susceptible to catching fire at elevated

temperatures, and must be handled extremely carefully. To prevent the molten
metal from catching fire, a flux is added to the molten metal. The flux can be
sulphur or chlorides and fluorides.

Page | 37
 INTERNSHIP REPORT

Once the melting is complete, a sample of the melt is subjected to optical

emission spectroscopy to ensure the presence of all required components in the
right quantity in the alloy.

Once this is done, the molten metal is poured into the mold. Usually,
copper powder is dusted on the top to ensure metal in the risers stays in the liquid
state for a longer duration.

Fettling section

The fettling section takes care of removal of the excess metal in the casting,
such as the risers, sprue and gating system. The section possesses horizontal and
vertical cutting machines with bimetallic band saw blades with 4 to 6 teeth per
inch.

After cutting the excess metal, the casting is subject to milling to smoothen
out the cutting marks.

The final casting is subject to in-situ fluorescent dye penetrant test for
presence of any surface defects. Following this, it is subject to radiography to
detect bulk defects. If the casting does not have defects, or it is within the limit
prescribed by the customer, it is cleared.

Products

The nonferrous and magnesium foundries are capable to produce

aluminium alloy castings of dimensions up to 1500 x 1000 x 1000 and weight up
to 400 kg and magnesium castings of dimensions as given below.

This shop produces sand casted Al alloy (Al-Cu, Al-Si) products.

Two types of casting i.e. sand casting and investment casting is done here.

Sand of required size is preheated to about 100degC to remove moisture.

Page | 38
 INTERNSHIP REPORT

To remove hydrogen gas, nitrogen gas is purged and the density of the mold is
checked if the density is less than 2.64 g/cc then it implies that gas is present and
use nitrogen gas to remove those unwanted gas.

Sand used is AFS 60 size.

Typical products are turbine blades, aero engine parts.

There is a sand reclamation plant in which the used sand mold is crushed by
vibration and then sent to furnace to remove the impurities and binders by
burning them to a temperature of 600 degC and then separating them using a
separator (based on the required size).

Magnesium foundry:

Fig: Magnesium being poured into mould

Capabilities:

 Intricate , large diameter , large surface area, thin walled (up to 5mm) sand
castings with narrow as cast internal oil passages 4-12mm diameter,
developed and qualified to stringent radiographic and dimensional
Page | 39
 INTERNSHIP REPORT

acceptance standards for helicopter, gear box , aero engines and other
aerospace applications. High strength airframe castings also produced.
 Castings produced in high strength Mg alloys such as MSRB (Mg-2Ag-
2RE-0.8Zr), RZ-5(Mg-4.5Zn-1.2RE-0.8Zr), and AZ-91C (Mg-9A1).
 Castings in advanced WE-43 alloy (Mg-Ytterbium).
Product range:

Tolerance
Cast type Size (mm3) (mm) Surface Weight (kg)

finish(µm)

1000*1000*60
Sand casting 0 ±1 - ±2 8-25 120

Metal mould 1000*600*100 ±0.5 - ±3 6-18 100

Page | 40
 INTERNSHIP REPORT

Precision Foundry:
The Precision Foundry manufactures investment castings which are also
called lost-wax castings. It is used for casting Aluminium alloys, Alloy Steel,
Stainless Steels and Cobalt and Nickel-Base Alloys.

The basic steps in lost wax castings are as follows:

1) The wax is injection moulded into a master die, made of Aluminium. It is

injected in such a manner as to cover the inner surface of the mould uniformly.
2) Multiple wax patterns are created and joined together by a wax gating system,
consisting of a runner and sprue, to form a ‘wax tree’. The wax patterns are then
dressed to make the wax look like the finished piece.
3) The wax tree is dipped into a slurry of fine refractory material (primary slurry),
like zircon sand. Any excess is drained off, to produce a uniform coating. The
fine material gives smooth surface finish and reproduces the fine details. Then it
kept for drying for 4 to 5 hours.
4)After that, it is stuccoed with coarser sand. The coating is allowed to harden for
4 to 5 hours.
The above steps are repeated to give the required thickness of coating. For
Aluminium alloys, 8 such coatings are required. For steels, 6 coatings are applied.
Binders, like colloidal silica, are used to hold the refractory material together.

5) The investment is allowed to completely dry, which takes about 16 to 48 hours.

It is then put into an autoclave to melt and remove all the wax.
6) Secondary firing is done to remove any remaining wax and moisture. The
investment is then preheated. This is done to increase dimensional accuracy of
the final casting.

Page | 41
 INTERNSHIP REPORT

7) The molten metal is produced by melting metal it in vacuum heating furnace

or resistance heating furnace. The liquid metal is sent for spectral analysis, to
check the composition.
8) It is then poured into the investment, which has been placed cup-upwards in a
tub filled with sand.
9)After solidification of metal, the shell is knocked out by means of vibrations.
10)The sprue is removed and the final casting is subjected to sand blasting.
The casting is near net which means that it is very close to the final shape
required of the product, reducing the need for machining.

Investment casting is practiced when the following characteristics features are

strictly involved:

 Intricate shape
 Close tolerances
 Small size
 High strength alloys
Patterns used for investment casting are injection moulded of either wax or
plastic. Paraffin and microcrystalline waxes are the most common base material
for patterns.

Infrastructure:
 Wax pattern injection machine
 Wax pattern assembly facility
 Ceramic shell preparation
 DE waxing autoclave
 Vacuum induction melting for super alloys
 Aluminium oxide grit blasting
 Induction air melting

Page | 42
 INTERNSHIP REPORT

 Heat treatment including vacuum heat treatment

Capabilities:
 Castings with cell wall thickness of about 1.5mm and tolerance of
±0.13mm/0.25mm
 High strength Al alloys
 Al-Cu-Ag, High strength low alloy steel, stainless steel, Co-Ni alloys
Products:
Tolerance in
Material Size in mm mm Surface Weight(kg)

finish(µm)

Al alloys 300*200*1.5 ±0.25 3.2-4.8 2

High strength
low 200*100*2 ±0.2 3.2-6.8 10

alloy steels, Co-

Ni

super alloy

Page | 43
 INTERNSHIP REPORT

Die shop:

In this shop the die required for the forge shop are manufactured.

The shape of die required is obtained from the development department. The
dies are manufactured by manually controlled cutting machines or by CNC.

This shop has a VMC i.e. vertical milling center.

The major difference between the precision forge and general forge is the
tolerance and the die.

In precision forge we use a die with a wedge of angle 5 degrees.

There are two routes for die making i.e. EDM route and other is CNC.

EDM is preferred for simple shapes.

The dies are checked by using plaster of Paris as the molten metal and checked
for cavity formation.

The coolant used is mixture of oil and water as it acts as lubricant and helps in
dissipating heat generated due to friction.

Tool steel of Rockwell C hardness 38-42 is the material for Al products and tool
steel of

Rockwell C hardness of 48-52 for Ti and steel.

Page | 44
 INTERNSHIP REPORT

RUBBER SHOP:

In pattern shop the pattern of the required final product is manufactured. In rubber
shop the aim is to produce rubber parts with good hardness and elasticity.

We have different grades of rubber in the rubber shop. (Grades

hardness). When we mix raw rubber with different chemicals we
get different hardness. Rubber mixing mill is used for mixing
raw rubber and other chemicals.

This Rubber is extruded in the form of thin wires which is used for
making ‘O-rings. Typical rubbers used are nitrile rubber, neoprene,
hypalon, EPDM rubber. Hydraulic press of 30MT – 150MT.

Process of making O-rings:

•The die of the extruder is heated to 140 degrees before extruding.

•Rubber is introduced and pressed with a pressure of 1500-2000 psi for 15 min at
170-200 degrees.

Page | 45
 INTERNSHIP REPORT

•After extruding we take the wired rubber to make ‘O’ rings.

•This extruded rubber is placed in different dies to produce different types

of ‘O’ rings. •This extruded rubber is pressed at a pressure of 2000psi.

•The ‘O’ rings are obtained in the cavity provided and the excess rubber which is
called flash is removed.

• POST CURING: Post curing is done to obtain required hardness.

The obtained ‘O’ rings are heated to their respective curing temperatures for a
given time. This is called post curing.

Two rolling mills at high temperature are used to produce sheets of thickness of
about 8mm. Pressure applied is about 2100 psi and temperature is 180oC.

Different rubbers are used based on the application, conditions i.e. silicone rubber
is used for low temperature application and Viton is used for high temperature
applications.

Testing equipment:

We use two types of machines here

1. Non-contact measuring machine

2. Dyana scan
Non-contact machine is used to check the diameter of the extruded wire used
for ‘O’ rings. For this we take a small piece of the wire and place it under the
microscope .We take 3 readings of the diameter in 3 different directions and
give the average diameter. That should match with the required diameter.

Dyana scan is used to detect cracks in the rubber components. Even if there is
a slight crack the product will be rejected. In this case we use 4X magnification.

Page | 46
 INTERNSHIP REPORT

Products produced:

Products Size
O-rings , seals & grommets, bushes, Up to 220 ID mm * 10 mm
bellows
Gasket, pad & washers Up to 300*300*120mm3
Metal bonded parts Up to 150*150*50 mm3

Page | 47
 INTERNSHIP REPORT

Development shop:
A company's research and development department plays an integral role
in the life cycle of a product. While the department usually is separate from sales,
production and other divisions, the functions of these areas are related and often
require collaboration.

This shop is the brain of the division which gives the route card or process card
which tells the way in which a given product is produced .i.e. the different process
through different shops it needs to go.

Capabilities:

 CAD/CAM for design of dies and engine blade forgings.

 2dimensional draft, 3dimensional modelling and CNC machine tools
program design.
 Computer simulation route used for designing gating, riser and feeding
system for castings.

New Product Research

Before a new product is developed development department conducts a

thorough study to support the project. The research phase includes determining
product specifications, production costs and a production time line. The research
also is likely to include an evaluation of the need for the product before the design
begins to ensure it is a functional product that customers want to use.

New Product Development

The research paves the way for the development phase. This is the time
when the new product is actually developed based on the requirements and ideas

Page | 48
 INTERNSHIP REPORT

created during the research phase. The developed product must meet the product
guidelines and any regulatory specifications.

Existing Product Updates

Existing products of the company also fall under the scope of development.
The department regularly evaluates the products offered by the company to
ensure they are still functional. Potential changes or upgrades are considered. In
some cases, the development department is asked to resolve a problem with an
existing product that malfunctions or to find a new solution if the manufacturing
process must change.

Innovation

The research and development team aids the company in staying

competitive with others in the industry. The department is able to research and
analyze the products other businesses are creating, as well as the new trends
within the industry. This research aids the department in developing and updating
the products created by the company. The team helps direct the future of the
company based on the information it provides and products it creates.

Objectives:

1. Design and develop components manufactured in Foundry and Forge.

2. Starting basic fundamental operations.
Responsibilities:

1. Feasibility study.
2. Cost estimation.
3. Constructive review. Develop a product drawing.
4. Test Schedule – Testing requirements approved by customer.

Page | 49
 INTERNSHIP REPORT

5. CAD/CAM, 3D modelling, simulation packages for gating system in casting

and die design.
6. Conducting trials.
Software’s used for modelling

Procast

Procast is foundry simulation software, providing coupled thermal-flow-

stress analysis along with unique metallurgical capabilities, for all casting
processes and cast able alloys.

Procast is a physics based computer program designed for the calculation

of fluid flow, thermal and thermo mechanical phenomena encountered during the
manufacture of metal castings as well as the resulting microstructural features
obtained in the cast components. A typical casting is produced by pouring liquid
metal into a suitably prepared mould cavity containing the topology of the part to
be manufactured. As a result of energy extraction through the mould walls, the
liquid metal cools and solidifies producing a consolidated metal part. The
soundness and overall quality of cast metal parts is strongly affected by the details
of the liquid metal flow during mould filling and of the time dependent
temperature field during solidification. Macro and microstructural characteristics
of the cast parts are determined by the flow and thermal history of the casting and
these in turn determine the mechanical and other physical properties of the
material.

The basic operation of the system is straightforward. The key modules are
called Mesh Cast, Precast, Procast and Visual Cast. The Mesh Cast module is
used to create the geometry and finite element representation of the casting
system (including mould, risers, gating’s, filters and the like)

Page | 50
 INTERNSHIP REPORT

Conclusion:
 Hindustan Aeronautics Limited, Bangalore- Foundry & Forge Division
manufactures castings, forgings, rolled rings, brake pads, shape memory
alloys and rubber products for applications in the aeronautics, defence,
locomotive, earth mover and other industries.
 This division supplies the products to the various other divisions of HAL
manufacturing Aircraft, aero-engines besides the space, defence, railways
and other heavy engineering industries with an aim to become a significant
global player in the aerospace industry.
 Having well-equipped facilities it provides competitive products and
services with regular quality check at each phase of manufacturing without
compromising the customers expectation.
 The aim of HAL is to achieve self-reliance in design, development,
manufacture, upgrade and maintenance of aerospace equipment
diversifying into related areas and managing the business in a climate of
growing professional competence to achieve world class performance
standards for global competitiveness and growth in exports.
 More importance is given to the quality of products as well as meeting the
demands with minimal loss of resources

Page | 51
INTERNSHIP REPORT

Page | 52