SOURCE: AFI
In a scathing report, the Comptroller and Auditor General of India (CAG) has exposed a significant lapse by the Defence Research and Development Laboratory (DRDL), a key arm of the Defence Research and Development Organisation (DRDO), in its procurement of 1,329 kg of C-103 material worth ?4.83 crore for the Hypersonic Technology Demonstrator Vehicle (HSTDV) project. The material, known to be incapable of withstanding the extreme temperatures generated in a scramjet engine, was deemed “unwarranted and wasteful,” highlighting critical flaws in DRDL’s planning and execution of a high-stakes defense technology program.
Sanctioned in March 2001 by DRDO, the HSTDV project aimed to develop a hypersonic vehicle capable of demonstrating advanced technologies, including a scramjet engine—a propulsion system that operates at speeds exceeding Mach 5 by combusting air at supersonic velocities. The project, envisioned as a cornerstone of India’s quest for cutting-edge defense capabilities, saw a feasibility study conducted by DRDL in September 2003. This study identified the scramjet engine’s combustor temperatures, ranging from 2,227°C to 2,527°C, as a critical engineering challenge.
To address this, DRDL evaluated two high-temperature resistant materials (HTRMs): Nimonic C-263 and Niobium C-103. The study concluded that C-263 could sustain the required 20-second flight duration, while C-103, with a maximum temperature resistance of 1,200°C (extendable to 1,370°C with coatings), was inadequate for the combustor’s extreme conditions. Despite this clear finding, DRDL proceeded to procure C-103, a decision that has now drawn sharp criticism from the CAG.
In September 2005, the Ministry of Defence sanctioned ?48.65 crore for a sub-project under HSTDV titled “Development of Scramjet Engine and Engine Integrated Airframe,” tasking DRDL with designing, fabricating, and testing a scramjet engine. In May 2006, DRDL designated C-103 as the HTRM for the engine’s inner layer and C-263 for the outer layer, projecting a need for C-103 to develop five engines. However, citing potential design changes and high costs, the Special Purchase Committee (SPC) recommended procuring C-103 for only three engines.
Consequently, DRDL procured 1,329 kg of C-103 material, valued at ?4.83 crore, between October 2007 and October 2008. Additionally, 3,660 kg of C-263 material was acquired for ?1.76 crore from December 2007 to February 2008. The C-103 material, with a 10-year shelf life, was intended to support the scramjet’s development but proved unfit for purpose during testing.
The CAG’s audit, conducted in March 2012, revealed glaring discrepancies in DRDL’s procurement strategy. Despite the 2003 feasibility study explicitly noting C-103’s temperature limitation of 1,370°C—far below the scramjet’s 2,527°C peak—DRDL went ahead with the purchase. Testing confirmed the material’s unsuitability, as it could only endure high temperatures for five seconds, falling short of the project’s 20-second flight test requirement. Of the 1,329 kg procured, only 107 kg was used, leaving the remaining stock unused and effectively wasted.
When questioned, DRDO headquarters responded in January 2016, attributing the non-use of C-103 to “severe oxidation issues” and a change in engine combustor design, which favored C-263 exclusively. DRDO further claimed that ground test data suggested C-103 could support longer-duration tests (100 to 200 seconds) with advanced anti-oxidation coatings. The CAG dismissed this justification as untenable, pointing out that DRDL was fully aware of C-103’s limitations from the outset. Moreover, the project’s focus on short-duration 20-second flights rendered speculative claims about longer tests irrelevant.
The CAG concluded that the ?4.83 crore expenditure on C-103 was unjustified, as the material’s failure was foreseeable based on prior studies. This procurement misstep not only squandered public funds but also delayed progress in a strategically vital project.
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