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˜ HAL, KORAPUT IN BRIEF

˜ PRINCIPLE OF JET OPERATION
˜ R-÷ ENGINE
˜ THE COMPRESSOR
˜ SPECIAL FEATURES
˜ MATERIALS USED
˜ MANUFACTURING PROCESS
˜ CONCLUSION
 HAL, K APU I
BI

˜ Hindustan Aeronautics limited (HAL) is a public

sector undertaking (PSU) under the Ministry Of
Defence and fully owned by GOI.

˜ One among the elite Navaratna companies and is

known as the HAL ENGINE DIVISION.

˜ aoth manufacturing & overhauling of various

engines like R-èèá R-
á  á  are done.
 PI
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˜ aasically four forces come into action in an

aero engine while flying:
½ LIFT

½ GRAVITY

½ THRUST

½ DRAG
PI
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It is based on the BRAYTON Cycle.
@he main components include:

DCompressor
DCombustion chamber
D@urbine
DExhaust Nozzle
 H ! P 
˜ It is a device which intakes air at low pressure and
compresses it to high pressure .
˜ aasically it is of two types:
Centrifugal flow type &
Axial flow type
 

GI

D@his is a Twin Spoolá Axial Flowá @urbojet Engine
fitted with After burner and a variable area Jet nozzle.

DIt powers the Ô
 

multi-role Fighter Aircraft.

D@he Engine has provision for an emergency After-

burner thrust boostá which can be selected below 4.5
KM altitude.

! P  P!II!AI

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DÔ
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D3
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DÔ
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D Ô  3
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 ÎHY AXIAL L Î ! P  ?

 Smaller frontal area

 Controlled compression ratio

 High compression

 Compactness &

 Overall efficiency
 ! P  UBABLY

THE DIFFERENT PARTS OF COMPRESSOR ARE AS

FOLLOWS:

XCompressor casing
XCompressor shafts
Xcompressor disc
XStator blades
XRotor blades
XDistance ring &
XLocking ring
 AIAL U
˜ @he material used for compressor manufacturing requires the
following properties:
Light weight
High temp. resistivity
Low wear rate &
High strength
˜ For this purposeá mainly high temperature resistive @i-based
a
or  alloys are used for blades and other parts.
˜ NIMONIC alloy is used for HPCR disc whereas BT9 is used for
manufacturing blades mainly.
˜ Except theseá st stageá
nd stage disc and shafts are made up of
STAINLESS STEEL.
 ! P II
 AIAL

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˜ Mainly there are two stages:

) LPCS (low pressure comp. stage)

) HPCS (high pressure comp. stage)

˜ Each stage sub-divided into two parts:

i) ROTOR PART : adds KE to the intake air
ii) STATOR PART: converts KE into pressure energy
 L Î PU ! P    
˜ LPCR CONSISTS OF:
a) st stage disc
b)
nd stage disc
c) 3rd stage disc
d) alades & Shaft.
˜ THE NUMBERS OF BLADES IN EACH STAGE ARE:
a) st stage-

b)
nd stage-45
C) 3rd stage-53
˜ In succeeding stages the size of blades decrease but their
numbers increase.
 A
UA!UI
G  LP!
˜ First of all the material are heat treated and forged and as
per technology.
˜ @he roughing operation is done in lathe and send for
pickling.
˜ After picklingá these discs are again sent to the lathe for final
dimensioning and then all the disc are sent for broaching
operation.
˜ aench work is done at the last stage for obtaining the final
dimension and surface finishing of all the disc.
˜ MAGNETIC INSPECTION is done only in the first & second
disc for detecting the crack in surface & all other disc are
sent for DYE CHECK.
HIGH PU ! P    
˜ HPCR CONSISTS OF:-
a) 4th stage disc
b) 5th stage disc
c) 6th stage disc
d) 7th stage disc
e) 8th stage disc
f) alades and shaft
˜ NUMBERS OF BLADES IN EACH STAGE ARE:-
a) 4th stage-57
b) 5th stage-65
c) 6th stage-66
d) 7th stage-78
e) 8th stage-74
 A
UA!UI
G  HP!

˜ NIMONIC material is used for HPCR parts because it is

subjected to high temp.

˜ All the operations are same as that of LPCR technology

& individual discs are assembled after manufacturing.

˜ One extra BALANCING operation is performed.

˜ Lastly the blades are inserted into dove tailed grooves of

the disc and form the complete HPCR rotor.
 ! P  !AI
G

˜ @he unit of compressor casing include 5 perforated

spacesá st stage casingá
nd stage casingá 3rd stage
casingá 4th -5th stage casing and 6th -7th stage casing.

˜ @he perforated spaces are intended to permit steady

operation of the compressor st stage at lower rates of
airflow and to widen the margin of stability of the LP
spool.

˜ @he casing box also contains bypass vanes and spacer

body both made up of aluminium.
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 A
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G  ! P 
BLA  

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Daoth rotor and stator alades are manufactured
through a sequence of operations from BT9 material.
 H AI
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G  BLA

˜ Forging-----> rough broaching -----> inspection----->

gang milling -----> belt grinding(emery) -----> oblique

milling -----> polishing -----> maintaining LT (leading &

trailing) -----> after sizing -----> centering -----> copy

milling(profile) -----> slotting(locking).

˜ Grinding is also carried out by abrasive mixed with wax. Sic
abrasive (grit-
) is used for titanium blades
 P!IAL PAI


˜ Some other special operations are carried out to

impose desired properties to the compressor
parts like:
 Electrochemical machining(ECM)
 Electroplating
 Heat treatment
 Shot peening &
 Non destructive testing(NDT)

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Ô



˜ Firstly
nd & 3rd stage disc are press together after
heating in electric furnace due to which they expandá
after that it is left for cooling.
˜ Shaft is inserted into the holes of
nd and 3rd stage disc
by interference fit.
˜ Similarly HPCR discs are also assembled and another
hollow shaft is inserted into it through which the 1st
shaft passes.
˜ Finally blades are inserted in broaching grooves and the
locking rings are assembled for fixing the blades.
˜ aoth stages are assembled as per twin spool
arrangement.
! P  ABLY
ABLY  A J 
GI

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