HAL to Upgrade Key Dhruv Helicopter Part After Probe Links It to Fatal Crash

Hindustan Aeronautics Limited (HAL) is moving to strengthen the manufacturing process of a key component in its ALH Dhruv helicopters after an investigation linked the part to the January 5 Porbandar crash, which killed three Indian Coast Guard personnel. The component, known as the Non-Rotating Swashplate Bearing (NRSB), plays an essential role in transferring pilot control inputs to the helicopter’s main rotor.

A multi-agency Defect Investigation Committee (DIC) examined the wreckage and confirmed that the NRSB had fractured suddenly during flight, causing the crew to lose control of the helicopter. Laboratory analysis described the failure as critical and instantaneous, leaving the pilots with no time to respond. After the crash, emergency inspections of Navy and Coast Guard Dhruv fleets revealed additional cracks and early fatigue marks in several swashplate assemblies.

Investigators determined that Dhruv helicopters serving with the Navy and Coast Guard operate in much harsher maritime conditions compared to land-based fleets. These helicopters face saltwater exposure, ship-deck landings, strong winds, and rapid mechanical load changes. According to the DIC, these conditions greatly increase wear and corrosion, especially on sensitive components like the NRSB. The investigation recommended that HAL upgrade and strengthen the manufacturing process to improve the bearing’s durability.

HAL has accepted the findings and begun making production modifications to the NRSB. Officials said the new approach includes enhanced material treatment, improved surface finishing, and stricter quality inspections. These changes aim to increase the bearing’s fatigue life and prevent similar failures in the future. The upgrade will be carried out on 28 Dhruv helicopters operated by the Navy and Coast Guard, and the work will be done in phases to ensure essential missions can continue.

Dhruv helicopters used by the Army and Air Force were not affected, as their operational environments do not expose the NRSB to the same level of corrosion or mechanical stress. Their fleets resumed flying after routine checks.

The development has also brought renewed attention to earlier remarks by HAL Chairman C.B. Ananthakrishnan, who had publicly stated that the Dhruv had “no manufacturing defects” and suggested that earlier mishaps were mainly due to maintenance lapses by the user agencies. The DIC’s findings do not indicate a design flaw in the helicopter itself but confirm that this specific bearing requires stronger manufacturing standards in maritime roles.

The Dhruv has been in service for over two decades and is widely used across the armed forces for transport, search and rescue, coastal patrol, and ship-based operations. While the helicopter has performed successfully in many missions, its maritime variants have faced higher mechanical stress and corrosion, contributing to periodic technical issues and temporary groundings in past years.

The DIC is still preparing its final detailed report, which will shape new inspection intervals, maintenance rules, and any additional engineering changes needed. For now, HAL and the armed forces say their focus is on restoring full operational confidence in the Dhruv fleet, especially for missions where reliability is critical.