SOURCE: AFI
In a groundbreaking development, researchers at the Indian Institute of Science (IISc) have unveiled a state-of-the-art fuel injector system for fighter aircraft. Designed using advanced 3D printing techniques, this high-shear fuel injector promises to revolutionize combustion efficiency in military aviation. With its ability to produce exceptionally small fuel droplets, it ensures optimal combustion, paving the way for enhanced performance in advanced fighter jets like India’s Advanced Medium Combat Aircraft (AMCA).
Fuel injectors are critical components of aircraft engines, responsible for delivering fuel in a finely atomized spray to ensure efficient and stable combustion. The IISc-developed injector outperforms existing commercial alternatives by achieving:
Optimized Flow Field Consistency: Ensures steady fuel flow, critical for high-performance jet engines.
Ultra-Fine Droplet Sizing: Produces significantly smaller fuel droplets, improving combustion efficiency.
Precise Spray Patterns: Enhanced spray geometry ensures uniform distribution, leading to better combustion consistency.
Improved Flame Stability: Results in a more reliable and stable combustion process under varying operational conditions.
The fuel injector was developed using cutting-edge 3D printing techniques, allowing researchers to achieve intricate geometries and precise tolerances not possible with conventional manufacturing methods. The ability to prototype and test rapidly using 3D printing shortened development timelines while offering superior design flexibility.
“The high-shear fuel injector demonstrated superior performance across all key parameters, including droplet sizing, spray pattern formation, flame stability, and flow field consistency,” said an IISc researcher involved in the project.
The injector underwent extensive testing under simulated fighter jet operating conditions, including high-speed airflow, variable altitudes, and rapid changes in fuel flow. These tests confirmed the injector’s ability to maintain superior performance, even under extreme environments often encountered by military aircraft.
The IISc injector is expected to play a pivotal role in India’s Advanced Medium Combat Aircraft (AMCA) program, a fifth-generation stealth fighter currently under development. The AMCA demands cutting-edge propulsion technologies to achieve its goals of high maneuverability, supersonic speeds, and reduced radar cross-section.
Beyond the AMCA, the IISc fuel injector has the potential for integration into other aerospace and defense projects, including unmanned aerial vehicles (UAVs), advanced missiles, and space propulsion systems. The success of this project opens doors to further research in combustion optimization and additive manufacturing for high-performance aerospace applications.