Foundry & Forge Division Bangalore

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:

  • Aluminum 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


Product Range

Process Size in mm (max) Weight in kg. Tolerance in mm (range) Surface finish in um.
Blocker Forgings (Hand Forgings)
Aluminium Alloys 800 *    250 * 100 50 ± 5 10 to 15
Magnesium Alloys 600 *    250 * 100 25 ± 5 10 to 15
Copper Alloys 300 *    175 * 150 70 ± 5 10 to 15
Steel 300 *    175 * 150 65 ± 5 10 to 15
Closed Die Forgings
Aluminium Alloys 650 *    200 * 175 20 ± 0.5 to    ± 2 3 to 5
Magnesium Alloys 600 *    200 * 150 10 ± 0.5 to    ± 2 3 to 5
Copper-Base Alloys 600 *    175 * 150 45 ± 0.5 to    ± 2 6 to 8
Steels 600 *    175 * 150 40 ± 0.5 to    ± 2 6 to 8
Large Precision Forgings (Fan Blades)
Aluminium Alloys 800 *    200 * 150 05 + 1 / -1 3 to 5
Mandrel Ring Forgings
Aluminium Alloys 750 *    600 * 140 50 ± 3 Machined
Finish Copper-Base Alloys 600 *    500 * 100 70 ± 3 Machined
Steels 600 *    500 * 125 70 ± 3 Machined

General Forgings

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 water 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
  • Small volume, high quality job;


Product Range

Process Size in mm (max) Weight in kg. Tolerance in mm (range) Surface finish in um.
Blocker    Forgings (Hand Forgings)
Aluminium    Alloys 800 *    250 * 100 50 ± 5 10 to 15
Magnesium    Alloys 600 *    250 * 100 25 ± 5 10 to 15
Copper    Alloys 300 *    175 * 150 70 ± 5 10 to 15
Steel 300 *    175 * 150 65 ± 5 10 to 15
Closed    Die Forgings
Aluminium    Alloys 650 *    200 * 175 20 ± 0.5 to    ± 2 3 to 5
Magnesium    Alloys 600 *    200 * 150 10 ± 0.5 to    ± 2 3 to 5
Copper-Base    Alloys 600 *    175 * 150 45 ± 0.5 to    ± 2 6 to 8
Steels 600 *    175 * 150 40 ± 0.5 to    ± 2 6 to 8
Large    Precision Forgings (Fan Blades)
Aluminium    Alloys 800 *    200 * 150 05 + 1 / -1 3 to 5
Mandrel    Ring Forgings
Aluminium    Alloys 750 *    600 * 140 50 ± 3 Machined
Finish    Copper-Base Alloys 600 *    500 * 100 70 ± 3 Machined
Steels 600 *    500 * 125 70 ± 3 Machined

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 finidhing mills
  • Process shop for degreasing, etching, electropolishing and size-etching operations
  • Fluroescent 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-gaugung 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-base 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 Flurosilicone 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.


Product Range

Product Size (max) in mm
'O' Rings, Seals, Grommets Up to 220 ID * 10 mm
Bushes, Bellows, Boots, Pads, Washers, Gaskets, Metal-Bonded Items Up to 300 * 300 * 10 mm Up to 150 * 150 * 50 mm

Rolled Rings

The 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)
  • A 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, Nondestructive 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.


Product Range

Materials Finish Dimensions ( Range)   Maximum
Weight
Surface / Height
Aluminium    alloy OD:  400-3000 mm 1200 kg Machine    Finishing-400 mm
Carbon and Alloy Steels OD: 400-2400    mm 1000  kg Machine    Finishing-400 mm
Stainless Steels/Marging Steels OD: 400-2000    mm 800   kg Machine    Finishing-350 mm
Titanium Alloys OD:400-1000    mm 100   kg Machine    Finishing-300 mm
Nicket bas Super Alloys OD:400-600    mm 50   kg Machine    Finishing-300 mm