This document provides information about an industrial training program at HAL (Accessories Division Lucknow) in India. It describes the basics of fighter aircraft and facilities available at HAL, including various factories for mechanical, fuel, and instrument production. Testing laboratories are also described, with details provided on non-destructive testing methods like liquid penetrant inspection, magnetic inspection, radiography, eddy current testing, and ultrasonic inspection.

1. INDUSTRIAL TRAINING
at
HAL
(ACCESSORIES DIVISION LUCKNOW)
Presented by-
Ayushman Jaiswal
Roll no-1140435053
4th year
DEPARTMENT OF MECHANICAL ENGINEERING

2. CONTENTS
1. BASICS OF AIRCRAFT
2. FACALITIES AT HAL
3. FACTORIES
• MECHANICAL
• FUEL
• INSTUMENT
• TESTING LABS
 Non destructive

3. BASICS OF FIGHTER AIRCRAFT

4. FACALITIES AT HAL
• Process
• Heat Treatment facilities for all types of steels, Aluminum alloys, Copper,
Nickel & Titanium alloys.
• Protective Treatment
• Treatment facilities of all types like Plating, Polishing etc.
• Welding
• Electron Beam, Argon arc, Spot & Seam welding equipment to facilitate
intricate welding on thin metal bellows, capsules, stator Packs, Brushes
etc.
• Diffusion Welding of Dissimilar materials and Micro Plasma welding
• Manufacturing
• Machining of components ranging from 0.29 to 450 mm dia with accuracy
up to one micron.

5. • Assembly and Test
• 8000 sq.mtrs of Clean/Air-conditioned room (class 10,000 with laminar
flow cabinets) where assembly & test activities for instruments, Hydraulics
and Fuel factories take place.
• Environmental laboratory
• Facilities for all types of Environmental testing as per requirements of BS,
MIL & JSS, available to meet regular requirements of type testing of all
types of units designed/developed in the in-house R &D centre.
• In addition the Lab also caters for the need of special type of testing for
Wheels, Hydraulic item etc. in dedicated test rigs/beds.
• Design Computer Centre with Unigraphic, Computer Aided Design &
Analytical Software Packages.

6. FACTORIES
• Mechanical
• Fuel
• Instument
• Testing lab

7. MECHANICAL
Different products made at mechanical factories are –
• Hydraulic accessories
• Environment control system
• Power Flying controls
• Ejection seats
• Wheel and Brakes
• Ejection release valve

8. FUEL FACTORY
• Products made, assembled and tested in fuel factory are as
follows:-
• Engine Fuel Control units
• Reheat Fuel & Nozzle Control units
• Centrifugal/Reciprocating Fuel Pump
• Control Valves & Fuel Distributors
• Hydraulic Pump

9. INSTUMENT FACTORY
Instrument Factory makes the following products:-
• Electrical Rotating Machines
• Barometric Instruments
• Gyroscopic Instruments
• Electrical & Electronic System & Controls
• Fuel Content Gauging System
• Oxygen System
• Ground Navigation System

10. NON DESTRUCTIVE TESTING LAB
LIQUID PENETRATE INSPECTION
• A liquid with high surface wetting characteristics is applied to
the surface of the part and allowed time to seep into surface
breaking defects. The excess liquid is removed from the
surface of the part.
• A developer (powder) is applied to pull the trapped penetrate
out the defect and spread it on the surface where it can be
seen Visual inspection is the final step in the process.

11. MAGNETIC INSPECTION
The part is magnetized. Finely milled iron particles
coated with a dye pigment are then applied to the
specimen. These particles are attracted to magnetic
flux leakage fields and will cluster to form an
indication directly over the discontinuity. This
indication can be visually detected under proper
lighting conditions.

12. RADIOGRAPHY
• The radiation used in radiography testing is a higher
energy (shorter wavelength) version of the
electromagnetic waves that we see as visible light.
The radiation can come from an X-ray generator or a
radioactive source.
• The part is placed between the radiation source and
a piece of film. The part will stop some of the
radiation. Thicker and denser area will stop more of
the radiation.

13. EDDY CURRENT TESTING
Eddy current testing is particularly well suited for
detecting surface cracks but can also be used to
make electrical conductivity and coating thickness
measurements. Here a small surface probes scanned
over the part surface in an attempt to detect a crack.

14. ULTRASONIC INSPECTION
High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws. Reflected sound energy is displayed versus
time, and inspector can visualize a cross section of
the specimen showing the depth of features that
reflect sound.