Isothermal Forging Technology

Isothermal forging technology refers to a closed-die process. The workpieces and dies get heated at the exact temperature to ensure that engineering parts formation happens without any temperature loss in these workpieces.

This technology was launched by the DRDO (Defence Research and Development Organisation) to assist in producing various phases of high-pressure compressor discs for aero engines from titanium alloy.

In this article, you will understand isothermal forging technology UPSC concepts to help you with your upcoming IAS exam.

Defence is an important and dynamic segment in the UPSC Syllabus. Candidates can get details about Isothermal Forging Technology launched by DRDO further below in this article.

Understanding Isothermal Forging Technology

In 2021, DRDO (Defence Research and Development Organisation) announced a fundamental action towards accomplishing the greatest aeronautical challenge that even countries like China are grappling to achieve. This introduction of isothermal forging technology is a breakthrough in the modern technology sector that comprises forming complex nickel-based and titanium alloys that can resist temperatures of more than 1,000 degrees Celsius.

In addition, developed by DRDO’s leading metallurgical laboratory, the Hyderabad-based DMRL (Defence Metallurgical Research Laboratory), this is essential for establishing self-dependence in India’s aero-engine technology. With this technological expansion, our country joined the league of restricted global engine designers to control the manufacturing capacities of such crucial aero-engine elements. Here are some of the key points about isothermal forging technology.

• In metallurgy, the forging procedure is usually known as assembling metal and improving its resilience by beating or pressing.
• Forging contains different kinds, and the most popular among them is isothermal forging technology.
• In isothermal forging technology, the manufacturers ensure keeping the die and the workpiece at the same temperature throughout the forging cycle.
• This isothermal forging technology is popularly used in forging titanium-based alloys and is best suited for the HPC (high-pressure compressors) discs employed in aero-engines.
• The fighter jet engine requires elements with the highest accuracy, as a little disfigurement can lead to massive impairment. The isothermal forging technology delivers the parts with the highest accurateness.
• The parts made through the technology are very near to the final (net) form, lowering the demand for exterior finishing.
• More than half of the manufacturing expense gets lowered by eliminating conventional finishing procedures like grinding or machining.

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Significance of isothermal forging technology

The Adour engine gets rebuilt in our country by HAL (E), Bengaluru, under a certified manufacturing contract with the Original equipment manufacturer (OEM).

Just like it happens in any aero engine, there is a need to replace the high-value HPC drum assembly after a set number of functions or in the case of impairment which is quite extensive and costly. An HPC drum is a highly underlined sub-assembly, and it further remains subjected to low process exhaustion and creeps at elevated temperatures.

Therefore, it is crucial to ensure that the raw materials and HPC drums must be of top quality to fulfil the set combination of dynamic and static mechanical properties. The methodology embraced by DMRL (Defence Metallurgical Research Laboratory) is standard and can be adjusted to create other comparable aero-engine elements.

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