SOURCE: IDRW.ORG
In a landmark achievement for India’s defense and aerospace sector, the Defence Research and Development Organisation (DRDO) has successfully developed the near isothermal forging technology, a critical capability for manufacturing high-pressure compressor (HPC) discs used in aero-engines.
This cutting-edge technology, developed by the Defence Metallurgical Research Laboratory (DMRL) in Hyderabad, enables the production of all five stages of HPC discs from difficult-to-deform titanium alloys using a unique 2000 MT isothermal forge press. With this breakthrough, India joins an elite group of nations with the expertise to manufacture such critical aero-engine components, marking a significant step toward self-reliance in aero-engine technology.
Aero-engines are among the most complex and technologically demanding systems in modern aviation, requiring precision-engineered components capable of withstanding extreme temperatures, pressures, and mechanical stresses. High-pressure compressor (HPC) discs are a vital part of these engines, responsible for compressing air to high pressures before it enters the combustion chamber. These discs must be made from advanced materials like titanium alloys, which are notoriously difficult to forge due to their high strength and low ductility at typical forging temperatures.
Near isothermal forging is a specialized manufacturing process that overcomes these challenges by maintaining both the workpiece and the forging dies at elevated temperatures (close to the forging temperature of the material) during the forging process. This technique minimizes thermal gradients, reduces material flow stresses, and enables the production of complex geometries with superior mechanical properties, such as enhanced fatigue resistance and dimensional accuracy. For aero-engine components like HPC discs, these properties are non-negotiable, as they directly impact engine performance, reliability, and safety.
The development of near isothermal forging technology was spearheaded by the Defence Metallurgical Research Laboratory (DMRL), a premier DRDO laboratory based in Hyderabad specializing in metallurgy and advanced materials. DMRL leveraged its state-of-the-art 2000 MT isothermal forge press—a rare and advanced facility—to perfect the process of forging titanium alloy HPC discs for all five stages of compression in aero-engines.
Titanium alloys, while prized for their high strength-to-weight ratio and resistance to corrosion, pose significant challenges in manufacturing due to their sensitivity to temperature and deformation conditions. The near isothermal forging process developed by DMRL addresses these challenges by ensuring uniform deformation and preventing defects like cracking or microstructural inconsistencies, which are common in conventional forging methods. The result is a set of HPC discs that meet the stringent quality and performance standards required for aero-engine applications.
Recognizing the need for large-scale production to meet the demands of India’s defense and aerospace programs, DMRL transferred the near isothermal forging technology to Mishra Dhatu Nigam Limited (MIDHANI), a leading public-sector undertaking specializing in the production of advanced alloys and materials for defense applications. The technology transfer was facilitated through a Licensing Agreement for Technology Transfer (LATOT), ensuring that MIDHANI could replicate the process and scale up production.
In a collaborative effort between DMRL and MIDHANI, a bulk quantity of 200 HPC disc forgings—covering various compressor stages—were produced using the isothermal forge press facility at DMRL, Hyderabad. These forgings have been successfully supplied to Hindustan Aeronautics Limited (HAL) Engine Division in Bengaluru, where they are being integrated into the Adour engine. The Adour engine powers the Indian Air Force’s Jaguar and Hawk aircraft, making this development a critical enabler for the maintenance, repair, and overhaul (MRO) of these platforms.
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