ALH-3 Dhruv Cleared for Flight: HAL’s Indigenous Helicopter Returns Stronger After Crash Probe

After a four-month grounding triggered by a tragic crash involving the Indian Navy, Hindustan Aeronautics Limited (HAL)’s ALH-3 helicopter has been officially cleared to fly again. The incident, which involved three helicopters, prompted a full investigation that led to several key findings—and major changes in how the fleet will be maintained and operated.

What Caused the Crash?

The primary cause was traced to improper ground taxiing techniques. Specifically, the use of aggressive cyclic inputs with minimal collective created excessive dynamic loads, leading to structural stress and a cracked swashplate. This critical failure mirrored issues seen in early Apache helicopters, where ground handling errors led to similar rotor failures.

In contrast, HAL recommends a gentler approach—light collective input with smooth cyclic control. This method reduces fatigue on essential components and has now been officially incorporated into revised pilot manuals and standard operating procedures.

ALH-3 Operations Resume—With Safety First

The Indian Army and Air Force are now set to restart ALH-3 operations using a structured, step-by-step plan guided by updated maintenance protocols. Notably, helicopters equipped with HAL’s SKY system were unaffected during the inspections and remained in service, underscoring the role of equipment configuration in long-term reliability.

Why Ground Handling Matters

The investigation also revealed that the ALH-3, often used in heavy-lift operations, is especially prone to mechanical fatigue. Frequent taxing and cargo movement add wear and tear to parts like the landing gear and swashplate.

Two ground handling techniques were analyzed, and only one was deemed safe for long-term use. These findings now form the basis of HAL’s updated maintenance guidelines—designed to reduce stress, extend component life, and improve overall flight safety.

Ship-Based Strain: A Hidden Challenge

HAL’s review also pointed to ship-based operations as a major stress factor. Landings on rolling naval decks expose the helicopter to constant pitch and roll, forcing the rotor system to make continuous adjustments. This creates complex loads that impact the landing gear and airframe.

To combat this, HAL is exploring better rotor control algorithms, pilot training, and structural reinforcements to enhance the helicopter’s resilience during maritime missions.

The ALS-DREW Variant: A Closer Look at Fatigue

Fatigue in the ALS-DREW variant has raised further concerns. HAL emphasized the need for real-time flight data, advanced fatigue monitoring tools, and predictive maintenance to proactively manage material stress.

Repeated stress cycles, particularly from aggressive collective inputs, are exposing deeper metallurgical issues that must be addressed with design improvements and better inspection protocols.

Strong Legacy, Stronger Future

Despite these challenges, the ALH platform remains solid. Its use by the Sarang aerobatic team, which pushes the aircraft to the edge of its performance envelope, demonstrates its durability and robust design.

However, these extreme conditions also reinforce the need for early detection of fatigue—especially in high-stress components like the swashplate, landing gear, and rotor system.

Strategic Comeback Amid Rising Tensions

With geopolitical tensions increasing in the region, the immediate return of the Dhruv helicopter is of strategic importance. Already a critical part of India’s military logistics and troop mobility, the Dhruv is a proven asset across the Army, Navy, and Air Force.

HAL has issued strict new safety advisories and is accelerating upgrades to get the fleet operational without delay. These developments have already had a positive impact—HAL’s stock has surged, reflecting strong market confidence in the helicopter’s renewed potential.

What’s Next for HAL and the ALH Series?

• Integration of real-time flight data recorders
• Thermal sensors and advanced diagnostics
• Updated fatigue life models for critical parts
• Variant-specific maintenance and flight guidelines

By applying modern diagnostic tools and enforcing correct operating practices, HAL is on track to greatly extend the life and safety of the ALH fleet.