GE F-404 Engine Shortage Stalls Tejas Mk1A Production at HAL's Nashik Facility

Hindustan Aeronautics Limited (HAL), the primary manufacturer of India's Tejas Light Combat Aircraft (LCA), is facing significant production delays for the Tejas Mk1A due to a shortage of F-404 engines from GE Aerospace.

This setback has impacted the planned rollout of the first Tejas Mk1A jet from HAL's new production line in Nashik, pushing the milestone from November 2024 to March 2025.

HAL currently produces 16 Tejas LCA aircraft per year at its two facilities in Bangalore. The Nashik facility, intended to boost production capacity with an initial output of five Tejas Mk1A jets annually (eventually increasing to eight), is now facing hurdles due to the engine shortage. This delay directly affects HAL's ability to meet the Indian Air Force's (IAF) order of 83 Tejas Mk1A jets, a contract worth ₹46,898 crore signed in February 2021.

The F-404 engine, manufactured by GE Aerospace, is the powerplant for the Tejas Mk1A. GE Aerospace has attributed the supply delay to global supply chain disruptions impacting the aerospace industry. This shortage affects not only the production of new aircraft but also the maintenance and upgrade of existing Tejas aircraft requiring engine replacements or overhauls.

This delay raises concerns about HAL's ability to meet its delivery schedule for the Tejas Mk1A, a crucial component of the IAF's modernization plans. The Nashik facility was expected to alleviate pressure on existing production lines and expedite deliveries. However, the engine supply bottleneck has stalled these efforts.

 

[Akshat]

Bro it was IAF decision to choose the engine not ADA as other than f404 there are no other engines avilable at that time which are certified to use as single engine

Again, no. The engines are always chosen by ADA. Look at LCA mk2. DRDO issued the tender and made the selection. Look at the deal as well. The deal to develop and manufacture F404 IN variant was also signed between ADA and GE. And for the latest mk1a deal, it was signed between HAL and GE. IAF was nowhere in the picture.

 

[Anonymus]

Again, no. The engines are always chosen by ADA. Look at LCA mk2. DRDO issued the tender and made the selection. Look at the deal as well. The deal to develop and manufacture F404 IN variant was also signed between ADA and GE. And for the latest mk1a deal, it was signed between HAL and GE. IAF was nowhere in the picture.

Again Iaf chose engine but iaf don't produce those engine so deal was signed by HAL and ge. ADA is designing bureau it design aircraft according to iaf requirement and requirement are set by iaf not ada. If iaf required 85 kn thrust nothing ada can do in it IAF should asked for different power requirement.
And IAF has no fault in it too as IAF didn't knew when engine selection was done US-CHINA trade war and RUSSIA-Ukraine war would occur.
As many key components used in engine manufacturing like Titanium, yttrium, scandium etc larget producers are russia and china.
On top there are no engines avilable which are certified to use as single engine other than f414 and f404 which fulfills IAF requirement

 

[Anonymus]

Unprofessional of HAL selecting an egine production of which was closed.

who told ge f404 production was closed already used in f-117, gripen and in production for hurjet, t50, t7 etc. engine supply issue is because of Russia Ukraine war and US-CHINA trade war as many key components like-
1. Titanium which China is global leader in titanium production due to trade war and sanctions GE is unable to source titanium from China and Russia is 3rd largest producer.
2. yttrium and there largest producer are China and Russia. yttrium used in thermal coating of engines.
3. scandium largest producer are China and Russia.
And other engines like M88 and EJ200 are not certified for to use as single engine and same goes for Russian engine too except AL31 which is certified but to big to use in tejas. So other than F404 there no engines avilable in the market which can be used on tejas. Thus Iaf goes for f404 because no options are avilable.

 

[Arjun]

IAF didn’t choose the engines. ADA chose the engines. They placed orders. And in fact, IAF wanted Kaveri. DRDO failed to make them. Then IAF wanted mk2 but HAL failed to deliver. So they were forced to buy mk1a.

And indeed, that’s the problem. They don’t do the things they are supposed to do.

There was no engine option other than Kaveri or GE404..
And HAL/DRDO didnt delay Tejas Mk2.. the Govt delayed release of funds for Tejas Mk2 for 3.5years.. ur comments are always criticizing the HAL without knowing the basic facts in ground..

 

[Akshat]

Again Iaf chose engine but iaf don't produce those engine so deal was signed by HAL and ge. ADA is designing bureau it design aircraft according to iaf requirement and requirement are set by iaf not ada. If iaf required 85 kn thrust nothing ada can do in it IAF should asked for different power requirement.
And IAF has no fault in it too as IAF didn't knew when engine selection was done US-CHINA trade war and RUSSIA-Ukraine war would occur.
As many key components used in engine manufacturing like Titanium, yttrium, scandium etc larget producers are russia and china.
On top there are no engines avilable which are certified to use as single engine other than f414 and f404 which fulfills IAF requirement

Can you show us one single proof that IAF chose the engines? IAF doesn’t select the components. They select the performance. It should be supersonic, it should carry this much weight etc. It is ADA which chooses engines afterwards. So they could have chosen Russian engines or even EJ 200 which produces roughly the same thrust.

So IAF is not at fault. But DRDO is surely at fault for not making Kaveri even after a blank check funding.

 

[Sandeep]

While there is an engine delay issue we can still continue to manufacture the jets and simply install the engines as they arrive. Otherwise if HAL stops production and waits for the engines to arrive then the staff will be getting paid for doing nothing. As for opening a third production line the problem is that HAL can’t even manufacture to its current full capacity that it currently has. The best and fastest way to get the jets made on time and to a high quality is to get several private companies to manufacture the jets.

 

[Anurag]

Bro first please decide if IAF chose F404 or not. Then move to the next topic. You have this habit of deflecting to unrelated issues instead of settling the core issue. Core issue is that you said IAF signed the deal with GE but in reality it was HAL that signed the deal.

Ohk F404 won the tender by L1 the deal earlier later deal was for 99F404 was signed by GE and IAF!!

 

[Skyfall]

Indian pvt players like adani or reliance or tata or Mahindra should have initiated engine development activity in 2014. Indian private players have proved to be in competant

My friend private players need guarantee that MOD will purchase their equipment on regular basis. Unlike PSU companies they are answerable to share holders

 

[Sridhar]

Ohk F404 won the tender by L1 the deal earlier later deal was for 99F404 was signed by GE and IAF!!

IAF in this case is not the signatory to engine deal. It's between HAL and GE.

 

[Anonymus]

Can you show us one single proof that IAF chose the engines? IAF doesn’t select the components. They select the performance. It should be supersonic, it should carry this much weight etc. It is ADA which chooses engines afterwards. So they could have chosen Russian engines or even EJ 200 which produces roughly the same thrust.

So IAF is not at fault. But DRDO is surely at fault for not making Kaveri even after a blank check funding.

Can you show me proof that IAF didn't chose the engine.
Neither EJ200 nor any russian engine except al31and rd 93 is certified to use as single engine all russian and ej200 work in pair. And russian engines how much reliable they are you already knew about it.
DRDO has made Kaveri engine and successfully tested it's dry variant need more funds to develop it's wet thrust which IAF didn't provide funds for it for further development and even govt didn't support it. It required more than 1 or 2 billion usd to develop a jet engine while Kaveri only gets 600 million on half investment you get half result.

 

[Dredd]

Ohk IAF was more willing to accept EJ2000 but as for the things L1 was choosen!!
They really wanted something from it's own country by spending penies and when it comes to foreign they open their vaults!!
Really a well defined thinking that out us in the conditions where we are today!!

EJ200 competition was with F414 not F404 for tejas Mk2.

 

[Anonymus]

Ohk IAF was more willing to accept EJ2000 but as for the things L1 was choosen!!
They really wanted something from it's own country by spending penies and when it comes to foreign they open their vaults!!
Really a well defined thinking that out us in the conditions where we are today!!

EJ200 is not certified to use as single engine alone as there single engine capabilities are not tested and certified.

 

[Akshat]

Can you show me proof that IAF didn't chose the engine.
Neither EJ200 nor any russian engine except al31and rd 93 is certified to use as single engine all russian and ej200 work in pair. And russian engines how much reliable they are you already knew about it.
DRDO has made Kaveri engine and successfully tested it's dry variant need more funds to develop it's wet thrust which IAF didn't provide funds for it for further development and even govt didn't support it. It required more than 1 or 2 billion usd to develop a jet engine while Kaveri only gets 600 million on half investment you get half result.

How can I provide proof of something that didn’t happen? You show us the proof that it happened.

EJ was provided for mk2 and lost on price. So it works on single engine planes.

GoI gave a blank check funding to GTRE. Multiple extensions were given as well. As per the last audit, by Safran, the engine was totally useless and the whole hot core had to be replaced to make it suitable for LCA.

 

[Anonymus]

How can I provide proof of something that didn’t happen? You show us the proof that it happened.

EJ was provided for mk2 and lost on price. So it works on single engine planes.

GoI gave a blank check funding to GTRE. Multiple extensions were given as well. As per the last audit, by Safran, the engine was totally useless and the whole hot core had to be replaced to make it suitable for LCA.

Same how can I provide proof of something that didn’t happen?
EJ 200 was never used in any single engine planes so it's capabilities are unknown while here we are talking about mk1/1a not about mk2.
I am also saying GOI only provide 600 million used and to develop a engine 1 to 2 billion usd required.
"Safari ki kimmat me ferrari nahi milti"
Before you half brain write ki khane kaya chate ho i wrote that if you need full fledged engine you need to pay full fledged development cost for that engine.

 

[Akshat]

Same how can I provide proof of something that didn’t happen?
EJ 200 was never used in any single engine planes so it's capabilities are unknown while here we are talking about mk1/1a not about mk2.
I am also saying GOI only provide 600 million used and to develop a engine 1 to 2 billion usd required.
"Safari ki kimmat me ferrari nahi milti"
Before you half brain write ki khane kaya chate ho i wrote that if you need full fledged engine you need to pay full fledged development cost for that engine.

So you are agreeing IAF didn’t choose F404? That’s what I was saying.

EJ200 cleared the trials for mk2. It is also a single engine plane. We are talking about single engine planes, not mk1 or mk2. Point is that if it can work on mk2 then it can work on mk1, no?

GoI gave as much money as GTRE asked for. Money was left in the bank. GTRE had no clue what to do with the money.

“Jab break and clutch mai difference na pata ho to na Safari kaam aati hai na Farari”.

Before your half brain engine asks kehna kya chahte ho, let me clarify. If you need an engine then give it to someone who can make an engine.

 

[jagan.g]

Instead of depending on single engine fighters with high thrust imported engines, Can't we develop twin engine fighters based on medium thrust two Kaveri engines?.

 

[Satyendra pandey]

Never make any defence contract with any USA firm in future. Adopt low. Technology from other countries and upgrade that is better than the situation we are facing. Western countries specially Anglo sphere countries will never help you with positive intention. They will leave you in between and then act against you as an opponent unless you come under his umbrella and work as subservient to them.

 

[Dagger]

Real delay is from HAL. Where are the 3 trainer jets from mk1 deal for which engines were delivered in 2020 itself?

There is literally 12+ assembled mk1a fuselages and associated internal components waiting around for the engine. HAL indeed did whatever they could. The engines for the trainer jets were utilized for some other purpose.

 

[Akshat]

There is literally 12+ assembled mk1a fuselages and associated internal components waiting around for the engine. HAL indeed did whatever they could. The engines for the trainer jets were utilized for some other purpose.

Can you please show us the official proof of those 12 ‘literal’ fuselages? And while at it, clarify what the ‘some other purpose’ was when till March this year HAL was claiming to deliver all the trainers but then couldn’t deliver more than 5?

 

[captsai]

Again, no. The engines are always chosen by ADA. Look at LCA mk2. DRDO issued the tender and made the selection. Look at the deal as well. The deal to develop and manufacture F404 IN variant was also signed between ADA and GE. And for the latest mk1a deal, it was signed between HAL and GE. IAF was nowhere in the picture.

The reason for opting for 2 phased out engines at US of GE 404 & 414 by 2009 must be looked in apart from cost escalation since 2009 for both obsolete engines. Something wrong somewhere.

 

[Pratimesh Singh]

At this point I just feel bad for the IAF. And what is the government doing just waiting day by day so that our squadron strength decreases. They should have started getting aircrafts under MMRCA by now. But as usual so slow process.

 

[Chandrasekar Raghupathy]

I still say India is in big trouble.

We will get F404, F414 (TOT) only if we buy MRFA aircrafts, Stryker, MQ9 etc from USA.

America is taking advantage of India's current situation. The US is taking advantage of the fact that India is in a position to strengthen its air force after seeing the air forces of Pakistan and China. We have no choice now.

While we were designing aircraft like Tejas, AMCA, TEDBF, America should have designed without engine dependence.

Now if we have to change the design of our planes to suit the French and Russian engines, it will take another ten years.

The same F404 engine is going to countries like South Korea F50, Turkey Hurjet, Sweden JAS39, US Boieng saab Red Hawk and so on

India's current situation is very bad, the design of the aircraft cannot be changed and the engine cannot be changed. Engine and technology will not be available unless we buy American goods..

All that is story now, what are the mitigation plans, start working towards that, stop beating the chest, learn from China how to work on projects

 

[Arvind Sharma]

IAF didn’t choose the engines. ADA chose the engines. They placed orders. And in fact, IAF wanted Kaveri. DRDO failed to make them. Then IAF wanted mk2 but HAL failed to deliver. So they were forced to buy mk1a.

And indeed, that’s the problem. They don’t do the things they are supposed to do.

Because HAL would have kept profit margins even on the engines. They are authorised Mr. Minimum 15%.
Till now HAL has acted just like commission agent.

 

[Muthu.Kumar]

This IS the price to pay for being so lethargic and unwilling to learn from the mistakes after mistakes that we're committing.

First biggest mistake is putting the trust on GE - whis has the history of betrayal and backstabbing in the past.

That too Govt - Govt agreement ?
That too for only 80% TOT, when France offered 100%, giving up the fullest control (IP rights, export control etc.) ??

Can't avoid thinking that something wrong went behind the screen.

Second mistake is the failure to invest in and focus on Kaveri. Granted that past governments pathetically and unforgivably failed, but at least this govt. which is in power for the third term, should've made Kaveri it's priority, by pumping in more funds and bringing in the best and the brightest from the academia (and/or getting some help from abroad on consulting basis) to bring it up as THE engine.

Not sure if there was any plan B in situations like this or was a plan B possible, b/c HAL said that, Tejas was designed to be compatible only with GE engines. Seriously ? I mean, SERIOUSLY ??

At least, AT LEAST FROM NOW ON, I expect the govt. to aggressively push for indigenous R & D. Piggybacking on the others' shoulders only make as intellectually challenged. Then, there's no point in having such premier institutions as IITs, IISc et all.

The very phrase "MAKE In India" is wrong, which should've been "INNOVATIVE/RESEARCH/DESIGN In India", IMHO.

 

[captsai]

This IS the price to pay for being so lethargic and unwilling to learn from the mistakes after mistakes that we're committing.

First biggest mistake is putting the trust on GE - whis has the history of betrayal and backstabbing in the past.

That too Govt - Govt agreement ?
That too for only 80% TOT, when France offered 100%, giving up the fullest control (IP rights, export control etc.) ??

Can't avoid thinking that something wrong went behind the screen.

Second mistake is the failure to invest in and focus on Kaveri. Granted that past governments pathetically and unforgivably failed, but at least this govt. which is in power for the third term, should've made Kaveri it's priority, by pumping in more funds and bringing in the best and the brightest from the academia (and/or getting some help from abroad on consulting basis) to bring it up as THE engine.

Not sure if there was any plan B in situations like this or was a plan B possible, b/c HAL said that, Tejas was designed to be compatible only with GE engines. Seriously ? I mean, SERIOUSLY ??

At least, AT LEAST FROM NOW ON, I expect the govt. to aggressively push for indigenous R & D. Piggybacking on the others' shoulders only make as intellectually challenged. Then, there's no point in having such premier institutions as IITs, IISc et all.

The very phrase "MAKE In India" is wrong, which should've been "INNOVATIVE/RESEARCH/DESIGN In India", IMHO.

Very valid points and true. ADA was created as an autonomous agency to function & take decisions easily with integrated FA to fasttrack policies & contracts.
Unfortunately the decades of Colonial mindset and old loyalties is set into many Indians. Many are swung by foreign visits especially US. DRDO, ADA & Cabinet Committees are the ones who make policies passed by the RM. The PM, FM & RM can create an environment / platforms for ease of doing business by cutting red tape and old licence raj mind sets but people and entire work force right upto management across scientists, defence, ministries & buerocrats have to change and adopt without being subservient which is largely the order that prevails.
Even 2 or more parallel JVs like betwn HAL & Safra, ADA & RR or ADA & GE with full TOT and about 3 assy lines in 2 or more states is what policy makers need to focus on and make happen, given the sheer size and numbers of the needs of IAF / IN / IA & the new world of Drones, UAVs, cross small weaponised UAVs etc

 

[captsai]

High time the NMG (Numerical Master Geometry) of LCA Mk1A, TEDBA, AMCA etc are shared with our select PVT Aerospace agencies like Tatas, Reliance, Adani, Mahendra etc to in turn pursue JVs with aero engine manufacturers and establish MAKE IN INDIA AERO ENGINES