Ak-203 rifles to be fully Made In India as Kanpur Factory develops unique metal, required to manufacture these rifles
Marking a giant leap in India’s defence manufacturing, the Small Arms Factory (SAF) in Kanpur, Uttar Pradesh (UP), along with its metal suppliers, has developed a ‘unique metal’ that is at par with GOST (Gosstandart) standards used in Russian weapons like the AK-203. SAF is a key weapon production unit which operates under Ministry of Defence and is a part of Advanced Weapons and Equipment India Limited (AWEIL).
In an interview with News18, Surendra Pati Yadav, General Manager (GM) SAF, the unit which played a key role in Indianisation of AK 203, said this breakthrough will significantly boost the ongoing production of AK-203 rifles at Indo-Russian Rifles Private Limited (IRRPL), an assault rifle-manufacturing facility in Korwa, Amethi, UP and would help in the manufacturing of fully Make-in-India AK-203 assault rifles, a goal that, until now, seemed out of reach.
Role of AWEIL and why AK 203 are being locally manufactured
AWEIL, an Indian defence public sector undertaking, is an Indian shareholder of IRRPL, a joint venture with Russia’s Kalashnikov Concern, established in 2019 that aims to manufacture AK-203 assault rifles for the Indian Armed Forces.
“Production of AK 203 at IRRPL’s facility in India is a part of a multi-crore deal signed between India and Russia to acquire over 770,000 AK-203 rifles. Of these, more than 100,000 were to be directly imported from Russia, while the remaining 670,000 were to be locally manufactured at the Korwa factory in Amethi UP. So far IRRPL has successfully delivered a first batch of around 35,000 AK 203 rifles to the Indian Army, while the remaining rifles are to be delivered in batches until 2032,” the GM SAF explained while highlighting why AK 203 are being manufactured in India.
New metal to boost IRRPL’s AK 203 production
However, after the evolution of this new metal, Yadav said the batches of AK 203 rifles to be released after December 2024, would be truly made in India. “The first batch of locally made AK-203 rifles produced at IRRPL’s Amethi facility wasn’t fully Make-in-India as the metal used in the rifles were sourced from Russia as a part of joint venture. However, the upcoming batch will be entirely indigenous, with all components, from the barrel to springs, manufactured in India,” said Yadav.
Circumstances which led to the discovery
Russian weapons are highly regarded for their durability and reliability in harsh conditions and ease of maintenance. They are built using high-quality metal of GOST-standard, which is nowhere available in India and, hence, procuring GOST standard metal in bulk was a big challenge. “Unlike Indian weapons, which are typically made from metal adhering to either IS standards or of the Bureau of Indian Standards (BIS), Russian weapons are crafted from a special metal that complies with GOST standards. GOST is the Russian national standard that ensures a product meets the country’s strict quality and safety requirements. However bulk procurement of the GOST standard metal for the manufacturing of Indian AK203 emerged as a challenging task before us,” Yadav told News18.
It was then that a mission to develop India’s own metal at par with Russian GOST standard metal was launched to give AK 203 rifle local-manufacturing a new height. “We called a meeting of our metal suppliers and a challenge to develop a unique metal of specific composition that could rival the Russian GOST standard was thrown before them,” the GM SAF recalled.
The Eureka moment
Over six months, through rigorous tests and trials, technicians and metallurgy experts worked tirelessly to craft a special metal that met the required specifications. This new metal was significantly different from what was used in existing Indian weapons, but it reached the quality of Russian GOST-standard metal. “When we finally succeeded, it was a Eureka moment for us,” Yadav said. However, this breakthrough was just the beginning. The team had to overcome additional challenges in production to fully indigenise the AK-203, making it a landmark in India’s defence manufacturing.
Next challenge was to cast components of AK-203
With the development of the special Indian-origin metal complete, the next challenge was to cast the components of the AK-203 rifle in a way that preserved its strength and durability, ensuring performance at par with Russian rifles. “In July 2023, after successfully developing the metal, we faced the task of casting the rifle components. We decided to approach this in three phases,” Yadav said.
The first phase involved casting five key components of the AK-203 rifle. The second phase focused on 21 components, while the third phase dealt with 17 additional parts. Yadav proudly shared that phase one had been successfully completed, with trials already conducted. Phases two and three were nearing completion, with trials expected to be finalised by December 2024. “Similar to other components, these components would also be sent to IRRPL for the final assembly of the weapon thus making the AK-203 truly a Make-in-India product,” Yadav added.
What makes AK 203, one of the most lethal weapons?
The experts with the SAF while highlighting the specifications of the AK-203 said it is a modern, gas-operated assault rifle from the Kalashnikov series, designed for superior reliability and adaptability in diverse combat scenarios. “It is chambered for 7.62×39 mm ammunition, providing a balanced combination of firepower, accuracy, and control. With a weight of approximately 3.8 kg without a magazine, the AK-203 is lightweight and easy to handle. It features both semi-automatic and fully automatic firing modes, with a rate of fire of 700 rounds per minute. The rifle has an effective firing range of up to 800 meters, making it a versatile weapon for close-quarters as well as medium-range engagements. The AK-203 uses a 30-round detachable box magazine and is also compatible with extended or drum magazines,” the experts said.
However, in terms of durability, the experts said that the rifle boasts a chrome-lined barrel, ensuring longevity and corrosion resistance in harsh environments. It has a folding and adjustable stock for improved portability and user comfort, along with a Picatinny rail for mounting optics and accessories. With a muzzle velocity of 715 meters per second, the AK-203 is known for its exceptional durability, ease of maintenance, and reliability in challenging conditions. Its design prioritizes operational efficiency, making it a trusted choice for the Indian Armed Forces,” he added.
AK 203 rifles to resolve long-standing rifle issues of Indian Army
The induction of AK-203 rifles is expected to resolve the Indian Army’s long-standing rifle issues, which have persisted for over two decades due to multiple failed procurement attempts, often caused by unrealistic requirements. The Indian-made INSAS rifles have not met expectations in service, and the 72,400 Sig Sauer ‘Patrol’ rifles, initially procured, also failed to deliver satisfactory performance, leading to the cancellation of plans to order more.
The introduction of the AK-203 rifles, known for their reliability and performance, offers a much-needed solution. India is the first country outside of Russia to manufacture the AK-200 series rifles. Once the Indian Army’s requirements are fulfilled, there are plans to supply these rifles to paramilitary forces and explore export opportunities, marking a significant step in India’s defence manufacturing capabilities. The AK-203’s reliability, ease of use, and adaptability make it an ideal choice to address the Indian Army’s operational needs.
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