The Foundry & Forge Division has the infrastructure and expertise to manufacture radiographic quality castings to international standards. This section offers a wide range of materials and processes to meet the stringent specifications of customers.

Castings are designed using AFS solidification software for simulation. This software calculates the heat transfer during mould filling and solidifications on 3D solid models of the castings. This enables prediction of hot spots and helps in optimum riser design.

The main areas are :

• Alloy fabrication
  
  
• Semi-continuous cast billets
  
  
• Aluminium alloy castings
  
  
• Magnesium alloy castings
  
  
• Investment castings
  
  

Infrastructure

• Melting furnaces such as induction , resistance , gas and oil up to a maximum of 300 Kg capacity
  
  
• Degassing by mobile degassing unit
  
  
• Vacuum heat treatment
  
  
• Impregnation of castings
  
  
• 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
  
  
• Aluminium-lithium alloys
  
  
• Aluminum and magnesium base alloy metal matrix composites
  
  
• Software for feeding of casting
  
  

The General Forge Shop is the only one of its kind in India with the capability specifications of shape, size weight and number. 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 with extrusion capability and stand alone die heating furnace
  
  
• A 10-tonne counter blow hammer with a 500-tonne clipping press, a 1 tonne gravity drop hammer and pneumatic hammers of 1500 kg, 1000kg, 500 kg and 10 kg capacities.
  
  
• Cutting machines such as vertical and horizontal band saws, cold circular saws and abrasive cutting unit
  
  
• Battery of electrical resistance heated furnaces with temperature regulating devices.
  
  
• Shot blasting machine
  
  
• Heat treatment section with furnaces for hardening, tempering, solutionising, ageing, normalising and amealing with temperature controllers and recorders
  
  
• Full-fledged process and fettling shops
  
  

Unique Capabilities

• Forgings in all wrought alloys
  
  
• Open forgings, closed die forgings and material forged rings under one roof
  
  
• Post-forging processing facilities for forgings weighing from a few grams up to 7kgs
  
  
• Furnaces electrically heated to eliminate any chances of contamination
  
  
• Small volume, high quality jobs
  
  
• Argon atmosphere heat treatment furnaces for specific treatments
  
  
  

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
  
  
• A 1000-tonne direct drive screw press
  
  
• 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
  
  

The Powder metallurgy unit is the only one of its kind in India 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, 3000 tonne capacity hydraulic powder compacting presses
  
  
• Hydrogen atmosphere pressure Sintering Bell furnaces and continuous pusher furnaces
  
  
  

Unique Capabilities

• Indigenous development and manufacture of metalloceramic and organic brake pads, sintered bi-metallic bushes and clutch discs for aircraft, earthmover, automobile, marine and railway applications
  
  
• Development and manufacture of advanced metal matrix composites (MMC) such as AL-SiCp
  
  
• Unique dynamometer testing facility for assessing performance characteristics of friction materials and brake pads
  
  

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. The components with high performance ratings are including nitrile, neoprene, silicone, flurocarbon 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.

Infrastructure

• Sophisticated 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 very close tolerance limits of ± 0.02 to + 0.1 mm upto a size of 200 * 200 * 200 mm
  
  
• Development of rubber compounds to any specifications and pre-determined requirements
  
  
  
  

Four decades of serving the high technology segment of industry and a zeal to offer an extended range of products, motivated the Division to diversify into the manufacture of seamless 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 state-of-the-art ring mill is capable of manufacturing profiled rolled rings in variety of ferrous and non-ferrous alloys. The benefits of profile rolled rings are reduced input materials; desired grain flow along the rolled profile and improved metallurgical properties.

The unit has also the expertise and technology for manufacture of rings in marging steel, a strategic material used for defence and aerospace applications, with 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 Thyssen Wagner, Germany
  
  
• Battery of electrically heated low and high temperature furnaces (up to 2.2 metre diameter) with temperature controllers and recorders
  
  
• Quenching facility after rolling to substitute hardening cycle, wherever applicable
  
  
• A 500-tonne capacity ring expander
  
  
• Cheesing facility in the Forge shop in 3000 tonne Hydraulic Press and a battery to pneumatic hammers.
  
  
• Handling aids such as manipulators, forklifts and EOT cranes for heavy products
  
  
• Raw material cutting facility for up to 400 mm square sections in all alloys
  
  

Unique Capabilities

• Manufacture of rolled rings in all wrought alloys including super alloys up to 3.5 m OD
  
  
• In-house facilities for post-rolling operations including all types of conventional heat treatments, nondestructive and destructive tests, and also for optimising processes and rendering all technical support for meeting customer expectations for rings in advanced materials
  
  
• Ring expansion or compression for relief of residual stress in aluminium alloy rings up to one metre diameter
  
  
• Rolling of rings with either or both internal/external profiles, offering superior quality at competitive prices