SOURCE: RAUNAK KUNDE / NEWS BEAT / IDRW.ORG
India’s Gas Turbine Research Establishment (GTRE), a key laboratory under the Defence Research and Development Organisation (DRDO), has received approval for integrating the Dry Kaveri engine, equipped with a newly developed afterburner, into an older Limited Series Production (LSP) Light Combat Aircraft (LCA)-Tejas for validation testing, according to sources cited by idrw.org. This development marks a significant step in India’s pursuit of self-reliance in aero-engine technology, with parallel efforts underway to prepare the engine for final testing in Russia by 2028.
The Dry Kaveri engine, a non-afterburning variant initially developed for applications like the DRDO Ghatak stealth Unmanned Combat Aerial Vehicle (UCAV), has achieved notable progress. Recent ground trials have seen the engine generate 49-50 kN of thrust, surpassing its earlier target of 46 kN. With the integration of a new afterburner section, GTRE aims to boost the engine’s thrust to approximately 80 kN, a significant improvement from the 73-75 kN achieved in earlier demonstrations. This enhanced thrust is intended to position the Kaveri as a viable powerplant for modern fighter jets, including potential use in the LCA-Tejas Mk1A fleet.
The new afterburner module is under active development, with GTRE procuring critical materials to refine its design. The addition of the afterburner is expected to address previous shortcomings in thrust output, bringing the Kaveri closer to the performance levels of contemporary engines like the General Electric F404-IN20, which powers the LCA-Tejas Mk1 and delivers 78.7 kN with afterburner.
GTRE plans to integrate the Dry Kaveri engine with its new afterburner into an older LCA-Tejas LSP aircraft for flight testing. Two prototypes, designated PV-5 (KH-T2009) and PV-6 (KH-T2010), originally developed for the twin-seater variant of the LCA-Tejas Mk1, are being considered for this purpose. However, the Indian Air Force (IAF) has expressed concerns about using a single-engine platform like the LCA-Tejas for testing an uncertified engine, recommending either a twin-engine platform or an unmanned testbed to mitigate risks during initial flight trials. Despite these concerns, GTRE is moving forward with plans to use an LCA-Tejas LSP aircraft, leveraging its existing test results to demonstrate the engine’s flightworthiness.
The integration of the Kaveri engine into the LCA-Tejas is seen as a strategic move to validate its performance in a manned fighter jet, paving the way for potential future upgrades to the Tejas Mk1A fleet. If successful, the Kaveri with the new afterburner, expected to deliver 83-85 kN of thrust in its Kaveri 2.0 iteration, could serve as a domestic alternative to the F404-IN20 engines, reducing India’s reliance on foreign suppliers.
The Dry Kaveri engine is scheduled for its final testing phase in Russia, which will include high-altitude trials and runs on a Flying Test Bed (FTB). A modified Ilyushin Il-76, with the Kaveri replacing one of its four engines, will serve as the FTB for these tests, scheduled to commence in September 2025 at Russia’s Gromov Flight Research Institute. Previous high-altitude tests in Russia, conducted in October 2022 and February 2023, demonstrated the engine’s ability to achieve 48.5 kN of dry thrust, surpassing its simulated target of 46 kN. These upcoming trials will focus on validating the engine’s performance, endurance, and compatibility with aircraft systems under dynamic flight conditions.
The testing timeline aims for completion by 2025, with GTRE targeting final certification of the Dry Kaveri engine by 2032. Limited series production is expected to commence by 2025-26, with the engine initially intended for strategic applications like the Ghatak UCAV. The successful integration of the afterburner could expand its use to manned platforms, aligning with India’s broader defense indigenization goals.
Despite significant progress, challenges remain. The Dry Kaveri engine’s current weight of approximately 1,180 kg is a concern, as it is heavier than comparable engines like the F404 (1,036 kg) and F414 (1,110 kg), potentially impacting the LCA-Tejas’s agility and performance. GTRE is actively working on weight reduction through lighter alloys and advanced manufacturing techniques, with support from Indian firms like MIDHANI for material supply. Additionally, the afterburner’s development requires overcoming metallurgical and technical hurdles to ensure reliability and efficiency.
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