Where does India Stand in Aircraft Engine Manufacturing

Rohith Ram

Defence Research and Development Organisation (DRDO) has developed a technology to produce high-pressure compressor discs from titanium alloy which is seen as a crucial development for the defence sector. The DRDO has established the near isothermal forging technology to produce all the five stages of high-pressure compressor [HPC] discs out of difficult-to-deform titanium alloy using its unique 2000 metric tonne isothermal forge press. The technology has been developed by the Defence Metallurgical Research Laboratory (DMRL), a laboratory of the DRDO in Hyderabad.

“This is a crucial technology for establishing self-reliance in aero engine technology. With this development, India has joined the league of limited global engine developers to have the manufacturing capabilities of such critical aero engine components,” DRDO stated.

The methodology adopted by the DMRL is generic in nature and can be tuned to develop other similar aircraft engine components. The compressor discs produced using this methodology has met all the requirements specified by the airworthiness agencies for the desired application.

Accordingly, the technology was certified and letter of technical approval was accorded and based on the exhaustive component level and performance evaluation test results, the Hindustan Aeronautics Limited (HAL) and the Indian Air Force cleared the components for engine fitment.

Technology transfer
To meet the bulk production requirements, the technology has been transferred to Midhani through a licensing agreement and a bulk quantity of 200 numbers of HPC disc forgings pertaining to various compressor stages have been jointly produced and successfully supplied to the HAL, Bengaluru for fitment into Adour engine that powers the Jaguar and Hawk aircraft, the DRDO stated.

In India, the Adour engine is overhauled by the HAL under a licensed manufacturing agreement with the Original Equipment Manufacturer. Stating that in any aero engine, the HPC drum assembly has to be replaced after a specified number of operations or in case of damage, the DRDO added that the annual requirement of these HPC discs is quite large, warranting indigenization.

This technology is seen as a crucial development for the aircraft engine manufacturing industry. Now let us look at some of the trends that are driving the growth of this industry further.

Blockchain technology implemented in aircraft manufacturing
Digital technologies such as Blockchain are being adopted by aircraft manufacturing companies to monitor performance of aircraft parts and systems as the manufacturing process is highly specialized and complex. Blockchain is a data structure used to establish a digital archive or record blocks of data which can be accessed across a network of computers.

A leading aircraft manufacturing company has implemented IoT (internet of things)-driven blockchain to collect details about every component. This helps to predict maintenance events, optimize production operations and extend the lifetime of parts. The company has identified blockchain applications in the areas of supply chain tracking, procurement support and revenue sharing.

Machine learning algorithms in aircraft manufacturing
Aircraft manufacturers are using machine-learning techniques such as artificial intelligence (AI) to improve aircraft safety and improve manufacturing productivity. Machine learning algorithms collect data from machine-to-machine and machine-to-human interfaces and use data analytics to drive effective decision making. These technologies optimize manufacturing operations and lower costs.

One of the leading manufacturers uses machine learning and data analytics to identify faults in engines, which increases the components’ lives and reduces maintenance costs. The company has successfully built machine-learning algorithms to design aircraft and automate factory operations.

IoT (Internet of Things) technology used in maintenance
Aircraft maintenance and repair companies are widely using IoT technology for predictive maintenance of aircraft parts and equipment. IoT technology is used to send critical data from engines, wing flaps, bleed values and landing gear to technicians for preventive maintenance. This data aids technicians to create maintenance schedules, procure parts and schedule relevant workers to fix equipment.

3D printing for aircraft parts
Additive manufacturing is continuously evolving and manufacturers are now using 3D printing technology to produce parts for aircraft and aircraft engines. 3D printing creates a three-dimensional physical object using a digital design. 3D-printed parts are 25% lighter, simpler and offer more design features than conventional parts. This enables manufacturers to create high performance aircraft engines and parts.

One of the major setbacks for the industry right now is the Covid-19 pandemic and the effects caused by it.

Industry to focus on improving the supply chains
“The crisis confronting the aviation industry is not only unprecedented but also that no one who is working in the industry has any clue on how to put the industry back on track. It’s not a question of only restrictions, visas not being allowed, travel not being allowed, airlines not being allowed. Even after all these are allowed, there will be apprehension.

The first is the economic aspect. Will people travel, either for leisure or on business? The answer is clearly no. It will take a long time for this to happen,” says Jitender Bhargava, a former airline executive director, an aviation industry expert and consultant.

The demand for aircraft and restrictions on the movement of people and goods due to the pandemic has led to a breakdown of many essential A&D (Aerospace and Defense) supply chains. This has resulted in an impact on smaller suppliers, especially those with heavy exposure to commercial aerospace and the aftermarket business. As most A&D suppliers are highly specialized with unique expertise and complex equipment, it would be difficult to adapt to the different production needs in response to varying demand.

Moreover, the A&D supply base is not consistent, and the crisis will likely continue to affect suppliers in different ways, depending on whether they focus on commercial aerospace, defense, or the aftermarket. The challenge is highlighted as many suppliers serve both commercial aerospace and defense, and any irregularities from the commercial side could leave defense OEMs (Original equipment manufacturer) vulnerable with regard to sourcing critical parts for their programs and platforms.

Suppliers that depend primarily on the commercial aftermarket are expected to experience lower volume for several years due to reduced flying hours, an excess of used serviceable material, and inventory destocking. The industry’s focus is likely to shift toward transforming supply chains into more resilient and dynamic networks, which could be done using strategies such as onshoring, vertical integration, and increased cyber defenses.

To further strengthen supply chains, OEMs and suppliers should leverage digital tools, including automating internal processes and streamlining workflows, implementing smart management systems, and using data analytics. Also, collaboration with regional players to build capabilities and shift manufacturing capacity when needed could make the A&D supply chain more robust and help the industry manage business disruptions.

Many A&D companies are also using an ecosystem approach to strengthen their supply chains. In a recent survey, 72% of industry executives said they are investing in supply chain ecosystems to leverage external alliance partners.

Experts say that though the technology innovations are positives for the aircraft manufacturing industry, the pandemic situation and its effects are to be seen as an important effect and it will take a certain period of time to bring the industry back to the original state.