PAKISTAN AERONAUTICAL COMPLEX KAMRA

Submitted By:
Hassan Iqbal
Registration:
2020-ME-22

Mechanical Engineering department

UNIVERSITY OF ENGINEERING AND

TECHNOLOGY LAHORE
 INTERNSHIP REPORT

PAKISTAN AERONAUTICAL COMPLEX (PAC)

ABOUT:
The Pakistan Aeronautical Complex is one of the largest defense contractor in aerospace, military
support, and national security provider to the Pakistan military. Founded in 1971 by the Pakistan
Air Force (PAF), the PAC designs, develops, and builds aircraft and avionics systems for the
Pakistani military it also provides its services for civilian aircraft.
In addition, the PAC performs local maintenance and works on the aircraft MLU systems of
foreign-built military and civilian aircraft. It is solely owned by the Pakistan Air Force and its
corporate interests and its corporate appointments are directly made by the Chief of Air Staff from
the Air HQ.
In 1971, five years after induction of F6 aircraft in PAF, it was realized that the aircraft had started
falling due for overhaul and, in the absence of an in country overhaul facility, the aircraft would
be sent abroad for desired inspections, resulting in huge amounts of spending in terms of foreign
exchange and generating undesired downtime for the aircraft fleet. With this background, the
commanders of the Pakistan Air Force decided to goal of create an indigenous overhauling facility
for the F6 fleet of the PAF.
As a humble beginning, a single engine turbo prop trainer MFI-17 aircraft was chosen for
indigenous manufacturing. After successful negotiation with the Swedish OEM around 1975,
another factory was established.

As all these factories are co-located at Kamra, they were placed under the umbrella of Pakistan
Aeronautical Complex (PAC). To cater for this adverse situation, once again an indigenous facility
had to be established, so it was decided to establish Kamra Avionics and Radar Factory (KARF),
now known as Avionics Production Factory (APF). Once again under the umbrella of Pakistan
Aeronautical Complex (PAC).

The project culminated in production of a jet trainer co-designed and produced by Pakistan and
China in 1994. AMF is involved even today in manufacturing of about 20% of the structure of K-
8 at these facilities. This background of AMF was considered good enough to venture into the area
of indigenous production of a jet fighter aircraft. That is how AMF is now fully involved in the
notional program of co-producing JF-17 Thunder aircraft with China.
OPERATIONS AT PAC:
Since 1947, the Pakistan Air Force operated largely dependent on foreign suppliers, fighter jets
and aircraft had to be sent abroad for desired inspection, development, and to produce parts to
maintain the fighter aircraft in service, causing the downsizing of the air force.
After consultation from the PAF's commanders at AHQ at the Rawalpindi Cantonment, the
Pakistan Aeronautical Complex (PAC) was established in 1973 in Kamra with Aircraft Rebuild
Factory first being functional.

PAC was established by the Pakistan Air Force (PAF) as part of the new defense policy introduced
in 1972 the PAC represents wide range of corporate revenue of the air force while fulfilling the
national security needs of the country. The Pakistan Aeronautical Complex started with three main
Ministry of Defense projects designated P-721, P-741 and P-751.
The first two digits show the year of project approval and launch, the third digit is a serial
designator. Since 1980s–90s, PAC functions include licensed-built Mirage III, Mirage 5, and
the F-16s as well as building the F100 engines for the F-16s under license from Pratt & Whitney.

FACTORIES AT PAC:
 Aircraft Rebuild Factory
 Mirage Rebuild Factory
 Aircraft Manufacturing Factory
 Avionics Production Factory (APF)

SERVICES

 Aircraft manufacturing
 Aircraft overhauling & maintenance
 Avionics
 Electronics, radars & sensors
 Engine overhauling & maintenance
 Materials
 Systems & accessories
INTRODUCTION
It is a great honor for me to do an internship in the Technical organization ‘Pakistan aeronautical
complex Kamara’. Where organization gave their industrial exposure by following the decorum
and rules and giving me the chance to learn from their experienced staff members and employees.
The Organization has different sections such as AMF, ARF, MRF, and APF. Each section of the
PAC Kamra organization plays an essential role in its domain. This report will provide daily-based
information about the internship tenure of 2 weeks.

FIRST WEEK
On the very first day, after our entrance into the PAC karma. We were gathered in an auditorium,
where we are informed about the SOP of the state, and accommodation location and assigned to
the AMF Factory.

MRF (MIRAGE REBUILD FACTORY)

1. Introduction
Mirage Rebuild Factory, known as MRF, is a dynamic setup that undertakes variety of aircraft and
engine overhauls. The setup became a benchmark of MRO for western systems technology through
overhauling of Mirage aircraft for the last four decades. The factory undertakes complete MRO
solution from testing to overhaul of Aircraft components and major inspections of fixed wing
aircraft. MRF is responsible for structure repair of western platforms and weapon systems of PAF.
This also includes damage analysis and formulation of repair schemes.

These capabilities were instrumental in the recovery of Saab aircraft. MRF has pioneered aviation
coatings for airborne platforms of PAF and its upgraded facility meets European aviation
standards. MRF also upgraded PAF’s vintage platforms with modern Avionics suite along with
weapon integration. Air-to-Air Refueling capability in Mirage aircraft was undertaken by
acquiring state of art capabilities by MRF. MRF is also pursuing establishment of repair facility
for 4th generation helicopter to position PAC in MRO for rotary wing platforms.

In this regard, PAC will become an approved supplier for Leonardo helicopter division and
creation of a recognized maintenance center will serve as a regional hub for all types of scheduled
inspections and depot level repairs. Besides overhauling Mirage aircraft, MRF also overhauls a
variety of jet engines for PAF fleet with a comprehensive setup for inspection, repair, and
refurbishment of engine parts. This includes, overhauling of engines of Mirage, F-16, C-130, and
Karakoram-8 and T-37 aircraft. 170 engines are overhauled at MRF every year.
 2. MRF History
Mirage Rebuild Factory was established in 1974 for in country overhauling of Mirage aircraft and
has ever since evolved into a center of excellence for maintenance, repair and overhaul of military
aircraft and jet engines. With a number of quality accreditations and certifications to its acclaim,
MRF is trusted by leading aviation industries and air forces of the world. The dream of establishing
the Mirage rebuild factory came true, when the first Mirage aircraft rolled out after successful
overhaul in 1980.

CAPABILITIES OF AIRCRAFT GROUP

1. Aircraft Maintenance, Repair and Overhaul (MRO)

 Delta/GV inspection of Mirage III/V aircraft

 Depot level maintenance of Falcon DA-20 aircraft
 Depot level maintenance of Agusta AW-139 helo
 Mirage Pressure Refuelling (MPR) air to air refuelling modification of Mirage aircraft
 Hot harmonization of Mirage aircraft and its variants
 Aircraft Weapon and Avionics system Modifications
 Structure repair and wing overhaul of Mirage aircraft
 Structure repair of SAAB aircraft

2. Components Maintenance, Repair and Overhaul (MRO)

 Complete MRO setup for Mirage III/V aircraft components

 Martin Baker certified facility for overhaul of MK-4 and OM-6 Ejection Seat for Mirage
(III/V) Aircraft
 Trial repair of Non-Mirage components
 Depot level maintenance of JF-17 emergency oxygen system components
 Depot level maintenance of K-8 Aircraft starting system components
 Depot Level maintenance of C-130 Landing gear components
 3. Special Processes and Parts Manufacturing

 Aircraft painting according to American Federal 595 and French Air 8104 standards of
Mirage, F-16, JF-17, DA-20, Cessna, Mushshak, K-8, AW-139 and other light body
aircrafts
 Non Destructive Inspection (NDI) technique includes Penetrant Testing (PT), Magnetic
Particle Inspection (MPI), Ultrasonic Technique (UT), Radiography Technique (RT) and
Videoscopic inspection
 Capability of NDI of Mirage, SAAB, JF-17 and UAV aircraft.

CAPABILITIES OF ENGINE GROUP MRF

1. Special Processes
The special processes available at Engine Group include
1.1. (Surface Treatment) Electroplating
Repair and Fabrication Wing has the facility to accomplish Chrome, Nickel, Silver, Cadmium,
Zinc, Copper, Phosphate, Chromate, Alodine, Anodization, Electroless Nickel and Diffused
Nickel Cadmium electroplating up to maximum job size of 18 inches and the plating layer, ranging
from 0.0006 mm to 0.40 mm. Repair and Fabrication Wing has a facility of Anodization of
Aluminum & Aluminum Alloy coating up to the maximum size of 12 inches.
1.2. Heat Treatment
Heat Treatment processes includes Hardening, Annealing, Normalizing, Tempering, and
Quenching & Carburizing. Heat treatment furnace has its operating limit up to Max temperature
of 1150⁰C.
1.3. Machining
The following Machining processes are available
 CNC Turning (Vertical & Horizontal)
 CNC Milling
 CNC Grinding
 CNC Jig Boring
 Fitting (Threading, Drilling & Bush Fitting)
 Precision Machining
 1.4. Welding
The following Welding processes are available
 Resistance Welding (Seam, Spot)
 GTAW (Gas Tungsten Arc Welding) through
 Machine & Manual
 Brazing (Torch, Induction) Process
 SMAW (Shielded Metal Arc Welding)

1.5. Metal Process

The following Metal processes are available:
 Scribing
 Marking
 Cutting
 Fitting / Adjustment
 Riveting
 Blanding
 Re-working
 Grinding
 Trimming
 Planishing
 Re-shaping Dimensional Inspections

1.6. Thermal / Plasma Spray Coating

Flame Spray & Plasma Spray are available for Thermal Barrier Coating. The facility is NADCAP
& GE (AE) & Seneca certified. Plasma spray is used for dimensional buildup, up to 1.5 mm
thickness. Moreover, providing Wear and Tear Resistance, Corrosion Resistance and Heat
Resistance. MRF is certified for 13 Powders & 04 Wires advance Thermal Barrier Coating
techniques. Furthermore, HVOF (High Velocity Oxy Flame) capability is also available for Boeing
Aircraft parts.
1.7. Shot Peening
State of art automated Boeing certified facility is available for commercial airplanes as per set
standards. Following are the special features of this machine:
 Auto Rotation Fixture
 Precision Regulator Assembly with Electrical Controlled Motor
 Suction Blast Gun Assembly
 1.8. Painting
Following Painting, facilities are available:
 Thermostable Varnish
 High Temperature Silicone Paint
 Aluminum Pigment Paint
 Epoxy Silicone Paint
 Phosphate Primer (SF-3)
 Synthetic Resin Paint (Magnesium / Aluminum)
 Glycerodthalic Varnish
 Phenolic Varnish
 High Temperature Epoxy Paint
 Segmental Paint

1.9. Rubber Application

Following techniques of Rubber application are available:
 Silicone Rubber (Safe guard for metal)
 Sealant Application (Pre-air leakage)
 Anti-galling Compound (Corrosion Elimination friction)
 Segmental application (High Temperature Resistance)

1.10. Other Special Processes

 Plasma and HVOF Processes

 Penetrant Testing
 Magnetic Particle Testing
 Eddy Current Testing
 Ultra-Sonic Testing
 Radiography
 Radioscopy
 ASSEMBLY / DISASSEMBLY AND TESTING
FACILITIES FOR ENGINE AND ACCESSORIES

The capabilities related to Assembly / Disassembly and Testing Facilities for Engine and
Accessories include -
 Engines Assembly and Disassembly Docks
 Assembly and Disassembly benches for engine accessories
 Test Bed for ATAR, F100, TFE731 and Turboprop Engines
 Oil and Fuel Accessories Test Benches
 Special Bearing and Kinematics checking facilities
 Static and Dynamic Balancing Machines
 Inspection services for all engines at MRF

CALIBRATION PROCESSES
The Calibration Processes available at Engine Group include -
 Hygrometers
 Vernier Calipers
 Dial Test Indicator
 Gauge Blocks
 Weighing Scales / Masses
 3-axis Measurements
 Analogue / Digital Mustimeters
 Analogue / Digital AC / DC Power Supplies
 AC / DC Panels Meters
 Frequency Counters & Signal Generators
 Meggers / Insulation Meters
 Temperature Baths / Furnaces
 Temperature Gauges (with thermocouples)
 Torque Wrenches / Meters
 Pressure Gauges (Air/water/Hydraulic)

DOCUMENTATION PROCESSES
 The Documentation Processes of Engine Group consists of: -
 Engine production software for tracking of Engines, Accessories, Parts and sub parts
 Repair, Inspection, Assembly and Testing controlled through software
 Technical Order Distribution Office
 Method Design Offices, which establishes and controls Repair and Assembly schemes of
all parts and accessories.
 MRO
1. MIRAGE III / V AIRCRAFT OVERHAULING
Established since 1974, Mirage Rebuild Factory is the sole organization in Pakistan for overhauling
Mirage aircraft and associated components. It is capable to annually produce 12 aircraft and
more than 10,000 components on the average. MRF is fully capable to support complete Mirage
Fleet of Pakistan Air Force in accordance with OEM standards reducing the beyond country repair
to near zero. The OEM (Avions Marcel Assault Breguet Aviation) provides majority of the
procedures exercised for maintenance in the form of publications.
Aircraft overhauling at MRF is segregated into four major services:
 Aircraft Overhauling
 Aircraft Modification and Upgradation
 Aircraft Structure Repair
 Overhauling of Mirage Aircraft components
 All of the facilities are certified by AS9100 Quality Management System and directed by
a solid Quality Control System.

2. Overhauling of Airframe

Overhauling facility of Mirage airframe is a series of processes including de-painting, disassembly,

ageing analysis, inspection of complete aircraft structure with the help of various NDT methods,
renewal of electric looms control cables/rods and rigid pipes. All the aircraft systems hydraulic,
fuel, electric, mechanic, and pneumatic are refurbished during the overhaul process, followed by
on ground checks as per OEM laid down instructions in the form of work sheets. The aircraft is
re-painted after assembly and released for flying after successful aerial trials. All the maintenance
is documented and verified by Quality Control.
3. Maintenance of Aircraft Components

The components maintenance facility is established to overhaul components associated to various

versions of Mirage aircraft. The facility is capable to accommodate maintenance of all the
components of various aircraft systems. The services provided vary from simple bench check to
complete overhaul of aircraft components. The facility is further classified into 13 different
sections/shops as per job capacity. Components overhaul process involves disassembly, cleaning,
inspection, assembly and final testing. Each component is inspected as per process sheets deduced
from OEM prescribed maintenance manuals. Shops are well equipped with the related state of the
art equipment and testers to perform the inspections of components.
 4. Structural Repair and Painting

Structural repair facility was established to repair and refurbish any type of structurally damaged
aircraft. The facility is one of its types to recover aircraft and its structural parts damaged in
accidents. Repair of fuselage frames, wing fuel tanks refurbishment, structural reinforcement
modifications are the key capabilities of this facility. This facility performs the structural
inspection during the overhaul inspection of Mirage Aircraft and conducts repairs where ever
required. This facility is also responsible for repainting and painting of Mirage Aircraft and its
components.
5. Aircraft Modification and Upgradation

The main aim of this facility is up-gradation of avionics systems and accomplishment of other
modifications to improve the capability of Mirage weapon system. A team of skilled technicians
and officers is dedicated to this facility to ensure timely execution of prototype and serial
modifications. Air to Air Refuelling modification as well ROSE (Retrofit of Strike Element) have
been successfully carried out by this facility on Mirage Aircraft.
6. Depot Level Maintenance of FALCON DA-20 Aircraft

Pakistan Air Force also operates French origin Dassault Falcon DA-20 fixed wing aircraft. Mirage
Rebuild Factory has capitalized its decades of experience on French Origin Mirage Aircraft and
has successfully carried out indigenous Depot Level Inspections of Falcon DA-20 Aircraft for
complete PAF fleet.
7. Depot Level Maintenance of Agusta AW-139 Helicopter
PAF has recently modernized its SAR platform with state-of-the-art AW-139 helicopters. Owing
to future MRO requirement for this rotary wing platform Depot level maintenance facility has been
established at Mirage Rebuild Factory. OEM has also extended its support by certifying this
facility to conduct Depot Level Maintenance of all Military variants of AW-139 helicopter. By
establishing this facility MRF is contributing additional savings to National Exchequer.
8. ATAR Engine

Like the Mirage aircraft, the ATAR engine is also stripped down to individual components. All
components undergo a thorough cleaning process to remove the contaminants accumulated during
the flights on Components. The cleaning process helps in identifying the defects present on the jet
engine parts. The cleaned parts undergo non-destructive inspections to identify the existing
defects. Specialized radiographic inspection techniques identify even the minutest cracks existing
in the parts.
The radiographic machine is equipped with a robotic arm to position the part for accurate
identification of sub surface cracks. NDI techniques are available for identifying the microscopic
imperfections in aircraft and engine parts. Non-destructive inspections are also aided by a semi-
automated eddy current inspection machine. The machine runs its probes on the pre-defined
geometry of the part and identifies the existing defects. Use of the automated probes eliminates
the chances of human errors. Crack identification on the ferrous parts is also carried out by a state
of the art magnetic particle inspection machine to identify the subsurface cracks. Strict quality
inspections by highly qualified inspectors ensure identification of repairable areas on the engine
parts. Comprehensive repair schemes are deliberated by highly experienced engineers and parts
are reclaimed through specialized processes with highest accuracy.
Over a span of more than 30 years, MRF has inducted numerous state of the art technologies for
maintenance and manufacturing of aviation parts. Elaborate machining processes not only help in
reclaiming the parts requiring repairs but new parts are also manufactured to service the engines.
Maintaining the highest aviation standards in repairs and manufacturing of new parts is a hallmark
for the factory.
High velocity oxy fuel and plasma coating techniques are used for seamless build up of the parts
that wear out during operation of the jet engines. Parts reclaimed by these techniques are given a
new life and they get ready to be installed on the engines for the next span of their operation on
the engine. Part reclamation facilities include aviation standard welding facility. This facility is
used to reclaim hot section parts of different jet engines. Spot, seam and tungsten inert gas welding
techniques are used to refurbish the engine parts to the highest aviation standards. Pakistan
National Accreditation Council and ISO 17025 certified precision measuring equipment laboratory
is providing calibration services to keep the overhaul equipment ready to make precise
measurements. PMEL calibration in done as per ISO certification standard.
Overhauling the engine accessories is a vital support setup required for the successful overhaul of
any jet engine. Meeting up to the requirement, MRF has setup an elaborate system for overhauling
the accessories. The process begins with completely stripping up the accessory to the basic
components. The components undergo a series of elaborate cleaning and inspection steps and the
defective components are identified. As per the nature of defects, either the components are
repaired or replaced and then the accessories are finally assembled. The final step of overhaul is
comprehensive testing of the accessories.
MRF has a series of specialized testers which simulate the aircraft operating conditions and the
overhauled accessories are subjected to these conditions. During these tests stringent quality
control checks are carried out to ensure compliance to the required standards and only the
accessories passing all these tests are cleared for installation on the engine. Finally all these
accessories and components are installed back on the engine and the engine becomes ready for test
bed operation. The comprehensive setup for overhauling the ATAR 09C engine has ensured self-
reliance and all the engine parts and accessories are reclaimed at the factory without any help of
the foreign companies.
 9. T56 Engine

The capability of the Mirage Rebuild Factory has been enhanced over the years to overhaul the
engines of other military fighter, transport and trainer aircraft. In the same pursuit, a Rolls Royce
certified facility has been established for overhauling the T-56 engine of C-130 aircraft. Like the
ATAR engine, the overhaul journey of the T56 follows an identical process cycle for its
overhauling. All the parts undergo stringent inspections and reclamation cycle before they are
assembled on the rotors.
Before installation on the engine, the rotors undergo specialized static and dynamic balancing to
ensure vibration free running. During this operation all the weight imbalances are counterbalanced
by adding weights at precise locations. Finally the engine is given a series of test bed runs to gauge
its operational parameters and the results are compared to the laid out standards. During all the
tests, the operators keep a close eye on the engine to look for any defects or anomalies of the
minutest nature. After passing all the tests, engine is cleared for installation on the aircraft.

10. TFE-731 Engine

A continuous endeavor to enhance capabilities, has led to establishment of a state of the art
aviation overhauling facility for TFE-731 Honeywell engine of K-8 aircraft. After thorough
ground studies the first TFE 731 engine has been inducted in MRF for overhaul.

11. F100 Engine

In 1989, realizing the requirement of PAF to maintain newly inducted F-16 aircraft, MRF assumed
the huge undertaking of establishing the overhauling setup for F100 engines of F-16 aircraft. Pratt
and Whitney certified overhaul facility not only looks after all modules of F100 engine, but also
upgrades 200 type engine to more powerful 220E type engine and has upgraded the entire F100
engines fleet of Pakistan Air Force.
AMF (AIRCRAFT MANUFACTURING FACTORY)
1. Introduction
AMF was established in 1975 to undertake manufacturing of a primary flying trainer aircraft under
license from SAAB SCANIA of Sweden. The aircraft was named Mushshak, (meaning proficient)
and was initially produced from the kits provided by SAAB. After successfully producing 92
Mushshak aircraft, AMF acquired the status of Original Equipment Manufacturer (OEM) in 1981.
Within 40 years of its establishment, AMF has produced more than 345 Mushshak aircraft which
are successfully flying not only in Pakistan but also in foreign countries such as Saudi Arabia,
Oman, South Africa, Qatar, Nigeria and Azerbaijan. The Mushshak not only meets the requisites
of international aviation standards but also conforms to Pakistan and South African civil aviation
standards and that is why it is the front line aviation product of Pakistan. During the course of
manufacturing, AMF, in order to improve the design and performance produced an upgraded
version of aircraft in shape of Super Mushshak.
Equipped with Lycoming 260 HP engine, advanced avionics package, Garmin, Dynon and Genesis
Glass cockpit and side by side seating for instructor and student pilot, Super Mushshak forms an
ideal platform for a variety of roles. Short takeoff and landing distance, higher g load bracket,
excellent stall and spin recovery, enhanced structural life of 9500 hrs and above all excellent after
sales spare and structural repair support are some of the key features rendering super Mushshak
aircraft to be far superior than its contemporary primary trainer aircraft of same class.
The aviation industry in Pakistan has experienced a tremendous growth in last 30 years. Over the
years, AMF's stature as aircraft manufacturer grew manifold with successive capability
achievement to manufacture Jet aircraft trainer K-8 in late 80s, unmanned aerial Vehicle FALCO
in 2008 and the modern Jet fighter aircraft, named JF-17 Thunder. Today, AMF has the capability
of manufacturing structural parts and aero-structure assemblies such as the Horizontal Stabilizer,
Elevator, Vertical Stabilizer, Rudder and Front Fuselage of K-8 aircraft.
APF (AVIONICS PRODUCTION FACTORY)
1. Introduction
APF (Avionics Production Factory), formerly known as KARF (Kamra Avionics and Radar
Factory) made its modest start in 1983 as a Radar Maintenance Center for overhaul and rebuild of
ground-based radars. In order to sustain ever-growing fighter fleet with advanced avionics
production, life cycle maintenance of avionics systems were later taken up. In its journey of around
four decades, it has established itself as the prime avionics design, development and integration
setup in the country; transcending the conventional bounds of MRO activities and stood out as a
leading Radar and Avionics solution provider. Today APF has the capability to provide complete
solution from initial concept to product qualification. Major area of APF’s working include
following:-
 Ground radars maintenance, repair and overhaul (MRO)
 Avionics systems production
 Avionics life cycle support
 Avionics system design, development and qualification
 Avionics integration
 Full mission aircraft simulator

ARF (Aircraft Rebuild Factory)

1. Introduction
Aircraft Rebuild Factory (ARF) is one of the four factories of Pakistan Aeronautical Complex
Kamra. ARF is an “ISO 9001: 2015”, “AS 9100 Rev D” and ISO 17025 certified overhauling and
manufacturing complex; providing overhauling services, fabrication of aviation assemblies, after
sales services and engineering support to Pakistan Air Force and other valued customers around
the globe.
Vision
To acquire capability to develop MRO package for aerospace vehicles and components with
design, development and manufacturing capability for spares and gradually transitioning towards
components to achieve self-sufficiency in supportability. Developing a cluster of core
competencies to transform into an aviation standard certified aviation MRO facility.