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For most engineering applications, a combination of properties is always required in a given material. To achieve
these properties, it is necessary that in-depth analyses of processing-microstructure-property relationships of such
materials are carried out. Also, processing parameters of commercial materials produced by major production agencies/
companies are always proprietary in nature and such technologies are established through years of dedicated in-house
R&D efforts. By virtue of the aforementioned experience, DMRL has reached a position to determine such processing
details, and to make use of such data while producing the materials at the industrial scale. A variety of aluminium
alloys has been developed and produced under the technical guidance of DMRL in the recent past for critical defence
applications that include:
Akash Missile
Naval Warship
All these materials are import substitutes, and the indigenous production of these materials is associated with
significant cost savings. Today, it is with great happiness I can say confidently that indigenous aluminium alloys have
truly arrived on the Indian defence scene.
I am glad that DESIDOC has taken the initiative of bringing out an exclusive issue of Technology Focus on
aluminium alloy technologies developed by DMRL. This issue will help document the journey and provide an update
on recent products, applications as well as initiatives, which will help both the users and the designers in an effective
manner.
Dr Ashim Kumar Mukhopadhyay
FNAE, FIMMM, FASM
Outstanding Scientist and Associate Director
DMRL, Hyderabad
part of the missile fabricated using the tests. The F3 section successfully section assembly also got the approval
indigenous aluminium materials were qualified all the prescribed structural of NPOM, Russia.
subjected to the prescribed structural tests. The qualification tests of F3
utilised in SLBM-K4 flight trial held working schedule was earlier utilised M/s Siddhi Engineers, Ahmedabad
in 2014. Several of these indigenised to produce Alclad AA2219-T87 (who successfully produced the thin
components were further successfully plates at BALCO for BrahMos missile walled tubes of alloy BAPL5xxx for
utilised in successive flight trials. applications. BrahMos missile earlier using billets
from HAAL and mother hollow
The nose cap dome components
were made from 30 mm thick
Akash Missile tubes from OFAJ) produced the
AA6082 straight tubes for Akash.
AA2219-O (annealed) plates, and Akash, a medium-range surface-to- DMRL provided crucial metallurgical
later heat treated to the precipitation air missile, currently being produced inputs in terms of optimum alloy
hardening temper. One such for Air Force and Army is a ramjet composition, ingot quality check
component was successfully utilised propelled missile with air intakes procedures and billet acceptance
in SLBM-K4 flight trial held in 2017. manufactured from aluminium alloy criteria to the firm to procure billets
These nose cap domes will continually AA6082 seamless tube. This tube is and the resultant mother hollow tubes
be used in all future SLBM-K4 flight imported from various sources abroad of 122 mm OD and wall thickness
trials. as a straight tube of 114 mm OD, wall varying from 5 mm to 8 mm. Further
thickness of two mm and length as inputs, in terms of formulation of
Yet another component, i.e., 1500 mm. The tube is then bent as process schedules for the manufacture
alignment cylinder, made from per the design requirement and heat
20 mm thick AA2219-T87 plates, shall treated to the peak aged temper for
be used in the future flight trials of the actual application. AA6061-T6
SLBM-K4 missile. t=2.4 mm
Boat tail
Indigenised Al-Mg alloy DMR291A in the form of (a) as-cast ingots, (b) M plate (t = 25 mm),
and (c) H24 sheets (t=2 mm) produced at BALCO, Korba
(a) Sabot and (b) Tail fin, both machined from indigenised DTD5124-T651 extrusions, and
(c) hard anodised tail fin, and (d) a couple of hard anodised sabot petals
RDE40M-T7x51 sheets of thickness (a) 6 mm and plates of thickness (b) 20 mm produced at BALCO, Korba
Indigenised AA2519 (a) Slab, and (b) T87 Plates Top and bottom sides of the 15 mm thick AA2519-T87 plate subjected to the
(t = 15 mm) produced at BALCO ballistic test against 7.62 x 54 mm AP (I) ammunition
The forging stocks shall be utilised semi-products for such applications solution treatment furnaces, aging
to produce selected forged components are considerably greater than those ovens together with state-of-the-
in T7452 temper for indigenously required for missiles, armaments and art handling, inspection and testing
built combat aircraft applications. The armour applications. facilities for the production of
20 mm and 30 mm thick plates are aluminium alloys for all varieties of
being utilised for ballistic tests against Further, following the recent defence applications.
7.62 mm AP(I) ammunition for closure of the heat treatment
vehicle armour applications. facilities for sheets and plates of the Also, the current practice is
age hardening aluminium alloys that many of the components are
Table 1 summarises the details of at BALCO, Korba, there exists machined from thick plates and/or
the past and ongoing indigenisation currently no such facility in any of the forgings, leading to huge wastage of
activities of aluminium alloys with aluminium industries in the country. materials. This necessitates the use
DMRL as the nodal agency. Table 2 The processing of the maximum of closed die forging of appropriate
further describes the details of the thickness of the plates at BALCO was, capacity (35,000 T) to produce near
heat treatment conditions (/tempers) however, limited to about forty (40) net shape products.
to which the indigenised aluminium mm because of the limitations of the
alloys were subjected to. capacity of the plate stretcher. A committee on aluminium
materials, with members from
Although, DMRL had success On the other hand, plates having ISRO and DRDO, under a national
with the production of aluminium the maximum thickness of about one material policy initiative, is currently
alloys for a variety of critical defence hundred eighty (180) mm are required looking into the aforementioned
applications, as discussed, the for combat aircraft applications. infrastructure requirements. Hindalco
existing industrial infrastructure is further advocating for a similar
requires augmentation and/or Stretching machines of appropriate build-up of infrastructure through a
upgradation (wherever necessary) capacities to stretch rolled products joint government-private partnership.
for the production of a majority ranging from thin sheets (t = 0.5 As realised by all concerned, such
of the components required for mm) to thick plates (t = 180 mm) infrastructure is indeed critically
indigenously built combat aircrafts. are, therefore, required. These required for the development and
This is because the dimensions and equipments should be associated indigenisation of speciality, wrought
the surface quality requirements of the with suitable homogenisation and aluminium alloys in the country.
This monograph deals with the design of protective armour and appropriate
modules to withstand the impacting objects. The monograph systematically
describes an overview of the general principles of armour design, ballistic testing
standards for composites, an introduction into ceramic and polymer materials,
their processing and design concepts related to their use in developing practical
armour systems.
Table 1. Aluminium Alloys Produced using the Existing Infrastructure in Indian Industries
Alloy and Temper Production Agency Applications User Inspection
Agency (IA),
Certifying
Agency (CA)
Alloy :1201 (AA2219), AK4-1Ч HAAL, Aurangabad (cast billet and slab) BrahMos Supersonic Armed Forces MSQAA (IA),
(AA2618); Д16Ч (AA2124), AK6 BALCO, Korba (cast slab, sheet and Cruise Missile (Airframe) (Army, Navy and
(BAPL2xxx) & AMΓ6 (BAPL5xxx) plate) Air Force)
Temper: O, T31, T4, T6, T652, T81, OFAJ, Nagpur and CEL, Kharagpur NPOM
T83, T8511, T87 (extrusion and forging stock)
SIFL, Thrissur (forging) Russia (CA)
Semi-Product : Sheet and plate (with CHW Forge, Greater Noida (rolled ring)
and without cladding), rod, seamless NFC, Hyderabad & Siddhi Engineers,
pipe, seamless tube, forging, rolled Ahmedabad (seamless pipe & tube)
ring and profile BAE, Mysore (profile)
Sheet: AA2219-O and AA6061-O HAAL, Aurangabad and Hindalco, BrahMos Supersonic Armed Forces MSQAA (IA),
Hirakud Cruise Missile (Army, Navy and CEMILAC (CA)
Air Force)
Plate: Unclad AA2219-O Plate: BALCO, Korba Submarine Launched Navy RDAQA, Midhani
Unclad AA2219-T87 Ballistic Missile (Nose (IA), CEMILAC
cap dome and alignment (CA)
cylinder)
Seamless Tubes: AA6082-T6 Siddhi Engineers, Ahmedabad Akash Missile Army Project Akash,
QC(L&T), Mumbai
(Air intake tube) Air Force (IA)
Sheets: AA6061- O and BALCO, Korba New Generation Air Force RDAQA, Midhani
Anti-radiation Missile (IA),
AA6061-T6 (NGARM) (Airframe) CEMILAC (CA)
Sheets: DMR291A-H24 and Plates: BALCO, Korba and Hindalco, Hirakud Naval Warship Navy QAE(N), Kolkata
DMR291A-M (Superstructure) and DQA(N), Delhi
(IA), DNA (CA)
Sheets and Plates: RDE40M- T7x51 BALCO, Korba Sarvatra Bridging System Army CQA(E), Pune
Extrusions: DTD5124-T651 OFAJ, Nagpur and HAPP, Trichy FSAPDS Ammunition Army DGQA, OFAJ (IA),
(Hard anodised tail fin CQA (Metals) (CA)
and sabot components)
Extrusions: DMR 7xxx-T7651 and HAAL, Aurangabad, OFAJ, Nagpur and Indigenously built combat Air Force and RDAQA, Midhani
Forging stock: DMR 7xxx Forging: HAL, Bengaluru aircraft (Forging) and Army (IA), CEMILAC
DMR 7xxx-T7452 vehicle armour (CA) (ongoing
project)
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H24 Strain hardened (half hard) and partially annealed DMR291A, Sheet
T31 Solution treated, cold worked and naturally aged Alclad AA2219, Sheet
T451 Solution treated, stress relief by stretching and naturally Alclad AA2219, Sheet
aged
T6 Solution treated and artificially aged AA2618 & BAPL 2xxx, Forging and Extrusion
T651 Solution treated, stress relief by stretching and AA6082, Extrusion; AA6061, Sheet
artificially aged
T7X51 Solution treated, stress relief by stretching and RDE40M, Sheet and plate
stabilised by overaging DMR7xxx, Flat and forging
T81 Solution treated, cold worked and artificially aged Alclad AA2219, Sheet
T83 Solution treated, cold worked and artificially aged Alclad AA2219, Sheet
T852 Solution treated, cold worked by compression and AA2219 & AA2618 & AA2124, Rolled Ring
artificially aged
T87 Solution treated, cold worked (a minimum of 7 % but Unclad AA2219 and Alclad AA2219, Plate
not exceeding 8 %) and artificially aged
Note: Tx51, i.e., stress relief by stretching (1-3 %), Tx511, i.e., minor straightening after stretching and Tx52, i.e., stress
relief by compression (1-5 %) are applicable for various tempers, where x = 3, 4, 6, 7 and 8, whichever is applicable. Stress relief
by either stretching or compressing is provided following solution treatment. The exact details of the heat treatments utilised
to obtain reproducible and improved properties in the indigenised materials are proprietary in nature.
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I, Alka Suri, hereby declare that the particulars given above are true to my knowledge and belief.
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