GTRE Seeks IAF's Ilyushin IL-76 Aircraft for Flying Test Bed of Kaveri Derivative Engine (KDE) and AMCA Engine, Eyeing Indigenous Testing Capabilities

GTRE Seeks IAF's Ilyushin IL-76 Aircraft for Flying Test Bed of Kaveri Derivative Engine (KDE) and AMCA Engine, Eyeing Indigenous Testing Capabilities


India's pursuit of self-reliance in critical jet engine technology is set to take a major leap forward. The Gas Turbine Research Establishment (GTRE), a premier laboratory of the DRDO, has formally requested an Ilyushin IL-76 transport aircraft from the Indian Air Force (IAF) to serve as a dedicated flying test bed.

This move is aimed at accelerating the development of the indigenous Kaveri engine and the future power plant for the nation's ambitious Advanced Medium Combat Aircraft (AMCA).

The Ministry of Defence has engaged with the IAF to secure an older IL-76, a robust four-engine strategic airlifter, for this crucial national project. Establishing a domestic aerial testing platform is essential to breaking India's reliance on foreign facilities.

Currently, India depends on Russia’s Gromov Flight Research Institute for in-flight engine trials, a process that involves replacing one of the IL-76's native engines with the engine under development.

However, securing a slot at the Russian facility often involves a waiting period of nine to ten months, causing significant delays to development timelines.

The Kaveri engine program, first launched in the 1980s to power the Light Combat Aircraft (LCA) Tejas, has navigated a complex journey marked by technical hurdles and international sanctions. Despite these challenges, the program has been revitalised.

A non-afterburning variant, known as the Kaveri Derivative Engine (KDE), which produces around 50 kilonewtons (kN) of dry thrust, is scheduled for its first flight trials in 2025.

This engine is slated to power advanced unmanned platforms like the Ghatak combat drone. The knowledge and technology gained from this project are considered vital for the development of a 110 kN thrust class engine required for the AMCA, India's fifth-generation stealth fighter.

By creating its own flying test bed, India aims to streamline the entire engine validation process. Having a dedicated aircraft would significantly cut down on development time, reduce costs, and provide GTRE with greater autonomy over the testing cycle.

The IL-76, known as the 'Gajraj' in IAF service, is considered an ideal platform for this role due to its power, size, and ability to operate safely with different engine configurations, allowing engineers to gather critical performance data in real-world flight conditions.

Sources indicate that the Indian Air Force is expected to approve the proposal in the near future, aligning with the government's overarching 'Aatmanirbhar Bharat' (self-reliant India) policy in the defence sector.

This initiative is seen as strategically vital, particularly as regional security challenges grow with neighbouring countries advancing their own aerial combat capabilities. The establishment of an indigenous test bed signals a strong commitment from the defence ecosystem to achieve sovereignty in aerospace technology.

Nevertheless, significant challenges persist. The Kaveri program has historically struggled with developing advanced materials and achieving the high-thrust performance required for modern fighter aircraft.

Experts, including retired IAF Group Captain Ajay Ahlawat, have stressed the need for a next-generation "Kaveri 2.0" engine capable of producing over 100 kN of thrust to meet the demands of the AMCA and the Tejas Mk2.

The creation of an in-house flying test bed is a crucial step to rigorously test, refine, and validate new designs, potentially bridging these technological gaps and paving the way for a new era in Indian military aviation.
 
Nice news! That will not only accelerate the developments and save cost and time, but sharing of data with Russia will also help further. Long back, IAF should have donated one FTB and twin-engine MiG-29 for testing purposes. At last, it's happening, which means the Kaveri Engine with Afterburner is seriously being considered. This will be a good answer for foreign-dependent engines for Tejas MK1A, which cause delays and pressure tactics as well. Hope GE will learn from this and sign the GE414 deal quickly for local assembly with 80% ToT and an ecosystem developed around it, resolving all the hurdles.
 
Just like with cruise missiles, increased private sector role in defence, and SDR radios for aircraft, India always wakes up late for everything and anything.
 
At last, but long delayed. If the IAF refuses, it will only hurt itself as it costs money, and most importantly, time for multiple transportation of new engines to Russia for testing.
 
This is a possibility but these planes have been in service for over 35 years and are almost at the end of their lifespan as the air frames are old and that has a mandatory expiration date.

However there’s no firm commitment if they will try and develop a Kaveri 2 engine which that in itself will take a number of years to design, develop and manufacture. Then it takes a number of years to test that engine on the ground in different simulated environments and weather conditions. This is all mandatory before you even consider to install an engine and testing it on a flying test bed. To test an engine in a flying test bed requires hundreds of flights at different altitude, speed, weather conditions, environment and the danger here is that the planes air frame and lifespan will not last long enough to complete the number of hours that’s needed to test the engine.

They can try and upgrade and overhaul the plane which might increase the plane’s lifespan for a few years but not for long. It might be better to either use the most modern IL-76 we have in service as a test bed or buy a brand new version from Russia or buy a used and cheaper version of the IL-76 that they can find.
 
First convert old IL-76’s to dedicated EW platforms, we need at-least 10-15 of them, a tiny bankrupt porkie nation has 4 of them.
 
Better late than never. Fund more labs and universities for metallurgy research. Metallurgy for jet engines and for micro chips needs to be prioritized.
Finally, the taste of decisive victory with indigenous arms and technology has encourged proper thinking in government that should have done fifteen years back. Hope, doubts that were held of capability has been vanquished and full atmanirbhar is ignited in this country which has suffered trillions of dollars of brain drain as best and brightest left country as they were not wanted in India because of corruption and looting taking place in India.
 
For the first time, FTB conversion will anyway take one year. We would hardly make two or three engines in the next 30-40 years requiring FTB tests 50 times. In two decades, the engine might not even be jet-fueled, making this IL-76 obsolete already.
 
Nice news! That will not only accelerate the developments and save cost and time, but sharing of data with Russia will also help further. Long back, IAF should have donated one FTB and twin-engine MiG-29 for testing purposes. At last, it's happening, which means the Kaveri Engine with Afterburner is seriously being considered. This will be a good answer for foreign-dependent engines for Tejas MK1A, which cause delays and pressure tactics as well. Hope GE will learn from this and sign the GE414 deal quickly for local assembly with 80% ToT and an ecosystem developed around it, resolving all the hurdles.
MiG-29 is a small aircraft and would not make a proper test bed. Yes, it may work for the Kaveri engine, but for nothing else as there is no future growth.
 
We are delaying the process. It must be done 1-2 years back when Kaveri engine derivatives were undergoing final testing in Russia. Anyway, this is a highly appreciated approach by the Indian Government. Now we should make the Il-76 model ready for testing our indigenous engines in a mission mode and the cargo plane be ready within a year for the mentioned purpose. Don't waste any more time.
 
Nice news! That will not only accelerate the developments and save cost and time, but sharing of data with Russia will also help further. Long back, IAF should have donated one FTB and twin-engine MiG-29 for testing purposes. At last, it's happening, which means the Kaveri Engine with Afterburner is seriously being considered. This will be a good answer for foreign-dependent engines for Tejas MK1A, which cause delays and pressure tactics as well. Hope GE will learn from this and sign the GE414 deal quickly for local assembly with 80% ToT and an ecosystem developed around it, resolving all the hurdles.
Great news! I have seen that the Navy is a forerunner in providing their naval ships and aircraft carriers, and for the aircraft engine, the Air Force must give the IL-76 to DRDO. This will open many doors for the DRDO in developing new engines. In fact, this will enable DRDO and GTRE to use the latest technology in metallurgy with the help of the private sector, and I hope this will soon reduce our dependence on the US and Russia. But India must ask France to make the M-88 Engine of 90 KN in India by the time we streamline our production and R&D.
 
Finally! After long last, finally someone does this sensible thing! I mean, we are only about a decade and a half late, but better late than never.
 

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