DRDO Invites Private Firms to Machine Advanced Single-Crystal Turbine Blades, Contributing to India’s Indigenous Aero-Engine Development

In a significant step towards achieving self-sufficiency in critical aerospace technologies, the Defence Metallurgical Research Laboratory (DMRL), a key laboratory under India’s Defence Research and Development Organisation (DRDO), is seeking collaboration with Indian private sector companies.

The initiative, announced via an Expression of Interest (EoI) on April 19, 2025, invites development contracts for the precision machining of advanced aero-engine turbine blades and vanes.

The contract specifically focuses on High-Pressure Turbine (HPT) blades and vanes, which will be machined from single-crystal nickel superalloy castings supplied by the customer. This move is aimed at bolstering India's capabilities in producing crucial components for aero-engines domestically.

DMRL has been a pioneer in the development of sophisticated materials for India's defence needs, especially within the aerospace sector.

The laboratory has already successfully developed the complex technology for producing state-of-the-art Directionally Solidified (DS) and Single Crystal (SX) blades and vanes.

These are manufactured through a specialised vacuum investment casting process, which is vital for creating components for modern aero gas turbine engines that require high levels of efficiency, significant thrust, and reduced fuel consumption.

Made from advanced nickel-based superalloys, these parts are engineered to endure the extreme temperatures and stresses encountered in military aircraft and helicopter engines.

The Expression of Interest represents a strategic effort to involve Indian industrial partners in the highly precise task of machining these essential components.

Single-crystal (SX) technology, a capability mastered by only a handful of nations globally including the USA, UK, France, and Russia, offers superior material properties.

By eliminating grain boundaries within the metal structure, SX components exhibit enhanced resistance to creep (deformation at high temperatures) and fatigue, critical for engine longevity and performance.

DMRL has already demonstrated its proficiency in this area, having supplied 60 single-crystal HPT blades to Hindustan Aeronautics Limited (HAL) in 2021 for an indigenous helicopter engine development program. There are further plans to deliver a total of 300 such blades in five sets.

The current EoI calls for competent industrial entities to undertake the intricate machining of HPT blades and vanes using the pre-supplied single-crystal nickel superalloy castings.

This manufacturing stage demands sophisticated techniques to achieve the complex aerodynamic shapes and meet the exceptionally strict dimensional tolerances vital for optimal aero-engine performance.

These blades and vanes form the heart of gas turbine engines, including those intended for critical platforms like the Kaveri engine (designed for the Light Combat Aircraft Tejas), the Jet Fuel Starter (JFS) for the Tejas, and the Adour engine that powers the Jaguar combat aircraft.

DMRL has previously transferred related casting technologies to HAL's Koraput division, where the production of JFS castings has already commenced.

This machining contract is a vital link in the aero-engine production chain. It ensures that the initially cast components are meticulously finished to meet exact design specifications, which are crucial for ensuring airworthiness and operational reliability of the engines.

This initiative strongly aligns with the Indian government’s “Make in India” policy, which seeks to lessen the country's reliance on foreign suppliers for high-technology aero-engine components and concurrently cultivate indigenous industrial expertise and capabilities.

India's aerospace industry has historically depended on imported engines and their associated parts, a situation that presents both strategic vulnerabilities and economic burdens.

The indigenous Kaveri engine programme, for instance, which was conceived to power the LCA Tejas, has encountered developmental challenges, partly linked to mastering high-performance material technologies such as single-crystal blades.

By successfully developing these critical materials and now seeking private sector participation for their machining, DRDO, through DMRL, is not only advancing indigenous technological prowess but also creating valuable opportunities for Indian industries to make substantial contributions to national defence and security.

 

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[R. Singh]

Most important MIDHANI+ NAL should develop lighter alloy for core of Kaveri engine that can resist 1800+ degree temperature ! Can GTRE+ Bharat Forge+ Godrej+ L& T make a engine that can generate at least 80-90 KN wet thrust ?

 

[Senapati]

HAL KORAPUT is equiped with all facilities fir casting and machining and ceramic coating for HP and LP turbine blades used in Gasturbines of fighter jet engine.

 

[krish1]

What is more important in manfacturing turbine components is strict quality adherence with NO design deviation .The manufacturers may come with strong supporting documents for design deviations. DRDO under no circumstances shall accept. This will ensure high standard of manufacturing in India and we can not only outbeat German and Japanese in terms quality but also protect tax-payers money by not allowing benefit to manufacturers

 

[Cyrus]

Today Surat is the best centre for Single Crystal Diamond production.
Instead of Nickel alloy, go straight to diamond for 100% fail proof blades which are temperature, shock and creep resistant.
The Diamond cutting industry will cut the raw Diamond to shape. Don't waste time with traditional Blades used by conventional Gas Turbine manufacturers.

 

[suriyateja]

Both high temperature strength and light weight are oppose to each other, light weight very high temperature resistance together is not possible by nature, there is always a balance between high temperature strength and its density(weight)

 

[sanket]

Good work done by DMRL. Joining hands with private players who have experience in the global supply chain can provide hand-holding in the development and production of this aero-engine turbine blade.

 

[Rinne Tensei]

Why are they not making a consortium and building this thing together and faster?

 

[ramdas]

Late realisation after American politics to delay the F404 and F414.

 

[P.K Senapati]

HAL Koraput, which is making turbine blades for the AL-31 engine of the Su-30, is the right agency to develop and manufacture single-crystal turbine blades or directionally solidified turbine blades for the Kaveri engine for Tejas and UCAV.

 

[Sudha]

WOW! Waiting for this news for a long long time. Now there is a hope for indigenous aero engine. Talent meets exposure, anything is possible.

 

[Sudha]

Why are they not making a consortium and building this thing together and faster?

Because GTRE & DRDO want the credit for themselves. Having failed in their efforts they are now ready to accept help from the private sector.

 

[jayesh patel]

HAL Koraput, which is making turbine blades for the AL-31 engine of the Su-30, is the right agency to develop and manufacture single-crystal turbine blades or directionally solidified turbine blades for the Kaveri engine for Tejas and UCAV.

If Russian technology was that good, why would they chase American one? Do you know the life of a Russian vs. American engine? Forget about quality; a Russian engine does not even burn fuel efficiently. See the black smoke coming out of the MiG-29.

 

[Sandeep]

This is a major and very difficult achievement which requires a lot of knowledge, skills and experience to develop the blades.

However to turn this metal into an engine is more complex and will take some time. We should first develop and manufacture the dry Kaveri engine first and check it's performance while they test it. If it performs very well then we can try and develop an indigenous jet engine similar to the F404 standard.

 

[Leo red]

Don't just give invitations. Make it a national pride subject and publish it in such a way that those joining will be for the prosperity of our country, and those not joining will be losers. Force everyone, especially Ambani, Adani, TATA, etc., for this. Gujjus only react when it comes to national pride; otherwise, they keep on thinking just for earning money. Make it an earning topic. Get some professional Gujjus in defence economics. They know how to get these people on board. Remember, we need to change minds; don't consider defence as an expenditure subject. Instead, show earning potentials by promoting exports and allowing profit from it. It increases GDP, so there will be growth and finally resulting in developments.

 

[Leo red]

Remember, Ambani can have dinner with Trump. Adani is in Israel, as is Tata, who holds a good position in Europe. Tata has a strong hold with Boeing and Airbus. Ambani's scientist connections in Russia and the US are not a secret. Adani sits quietly with Israeli companies. They can hire top-notch brilliance from India and abroad, especially Russian and Ukrainian scientists. Their competitive HR hiring system can get all pieces together, which is not possible with the DRDO system. And in terms of resources and procurement, all are good in their contacts. Why? Because they are in Indian markets and are invested in and supported by our citizens. Now it's time for payback.

 

[Vicky]

Because GTRE & DRDO want the credit for themselves. Having failed in their efforts they are now ready to accept help from the private sector.

Well, that may be a presumption. Indian companies started R&D too late, except for a few like Tata, Bajaj, and Mahindra. The question should be asked of governments full of license raj, with pure focus on import and trade. With whom should DRDO collaborate from the 90s to 2015?

 

[james mani]

This is a major and very difficult achievement which requires a lot of knowledge, skills and experience to develop the blades.

However to turn this metal into an engine is more complex and will take some time. We should first develop and manufacture the dry Kaveri engine first and check it's performance while they test it. If it performs very well then we can try and develop an indigenous jet engine similar to the F404 standard.

Dry Kaveri engine ready, tested with low thrust of 54KN. F404 is 74KN thrust. The process may take 3 years more to reach maturity in consistent product with private help, like Godrej.