GTRE's Kaveri Engine Gets Green Light for Inflight Testing After Years of Ground Testing, Modifications, and Enhancements

In a major leap forward for India's indigenous aerospace capabilities, the Gas Turbine Research Establishment (GTRE), a lab under the Defence Research and Development Organisation (DRDO), has announced that the Kaveri engine has been cleared for inflight testing. This marks a pivotal moment in the Kaveri engine project, which has navigated a challenging path since its inception in the late 1980s.

Initially intended to power the Light Combat Aircraft (LCA) Tejas, the Kaveri engine encountered technical hurdles that led to its decertification for that project. Undeterred, the DRDO shifted its focus to developing a dry variant of the Kaveri engine, now destined for unmanned aerial vehicles (UAVs) like the Ghatak, India's stealth UCAV program.

After years of rigorous ground testing, modifications, and enhancements, the latest iteration of the Kaveri engine has shown promising results in reliability, thrust output, and operational stability. The engine has successfully completed demanding tests, including high-altitude simulations in Russia and extensive ground trials in India, meeting the performance benchmarks required for inflight testing.

The Kaveri engine currently achieves a dry thrust of approximately 49-51 kN, suitable for UAV applications. There are plans to integrate an afterburner to boost thrust to 73-75 kN for more demanding scenarios. The clearance for inflight testing follows a successful Safran audit in 2018, which indicated the engine had reached a maturity level suitable for aircraft integration, albeit on a limited scale.

The next crucial phase involves mounting the Kaveri engine on a flying test bed (FTB) for real-world performance evaluation. This will involve testing the engine's response to various flight conditions, its integration with aircraft systems, and its overall reliability in dynamic environments.

This clearance represents not only a technological achievement but also a strategic victory, propelling India towards self-reliance in aero-engine technology. It signifies a reduction in dependence on foreign engine suppliers, a critical objective for India's defence strategy and its broader aerospace ambitions.

While this is a significant milestone, challenges remain. The engine must prove its endurance, efficiency, and adaptability throughout extended inflight tests. The DRDO and GTRE are committed to refining the Kaveri, with plans for a Kaveri 2.0 that could potentially match or exceed the thrust of engines currently used by the Indian Air Force.

 

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[R. Singh]

If Kavari generate 70-75 Kn wet thrust then make twin engine Tejas-1B make Tejas-1A with Kaveri 2.0 generating 85-90Kn wet thrust !

 

[Senapati]

If present Kaveri dry is giving 50kN thrust after integrating afterburner of Brahmosaerospace can give additional 30kN thus Kaveri1 can give 80kN and go for TejasMk1 can replace GE F404.
Work can continue with Kaveri2 for a 85 kN engine.

 

[skyfall21]

If present Kaveri dry is giving 50kN thrust after integrating afterburner of Brahmosaerospace can give additional 30kN thus Kaveri1 can give 80kN and go for TejasMk1 can replace GE F404.
Work can continue with Kaveri2 for a 85 kN engine.

Kaveri is a dead horse, suitable for UAV only.

 

[sanket]

Very good news! Hoping it will produce a thrust of 73 kN with afterburner. Second, I hope the MIG-29 will be used as a testbed rather than one of the LSPs. The MIG-29, being twin-engine, will be safer. Data collected from the FTB will be crucial and important because it reflects real-world performance and overall reliability in a dynamic environment, unlike ground trials and high-altitude simulations. Finally, it should be fine-tuned to produce the desired thrust required currently in use by the IAF by using lightweight material to withstand high temperatures. This will also reduce the engine's weight. Second, Safran's audit in 2018, which indicated it reached a maturity level sufficient for aircraft integration, albeit on a limited scale, demanded an extra 500 million $ for engine development even after the Rafale deal offset clause, which DRDO thought was not viable. Maybe the French wanted royalties too. I again think MIDHANI, GTRE, ISRO & BrahMos Aerospace should come together to develop lightweight material to speed up developing the afterburner section.

 

[beencensured]

Very good news! Hoping it will produce a thrust of 73 kN with afterburner. Second, I hope the MIG-29 will be used as a testbed rather than one of the LSPs. The MIG-29, being twin-engine, will be safer.

Why MiG-29? It must then be retested in Tejas and certified. Further, the MiG-29 engine must be fitted differently, wasting more time, but Kaveri could eventually replace MiG-29 engines. Whereas Kaveri can be fitted on LSP Tejas or Ghatak properly. If Kaveri is being tested on Ghatak, that is important news too. But it needs to be tested, and time should not be wasted on Tejas too.

 

[d7609]

They have developed advanced materials already.
Nal has manufactured 2D 4th gen sic-sic cmc.
And Midhani has developed all other superalloys needed for casing , blisk , compressor blades etc.
If the testing is successful they will start to include advanced materials in Kaveri enough to boost it's afterburner thrust to 90kn.

 

[Bikramjeet Goswami]

Why MiG-29? It must then be retested in Tejas and certified. Further, the MiG-29 engine must be fitted differently, wasting more time, but Kaveri could eventually replace MiG-29 engines. Whereas Kaveri can be fitted on LSP Tejas or Ghatak properly. If Kaveri is being tested on Ghatak, that is important news too. But it needs to be tested, and time should not be wasted on Tejas too.

Can't test an entirely unproven engine on a single engined fighter. Will probably be shipped to Russia for testing in specially modified 4 engined Ilyushin 76.

 

[Anupom]

Where is our own FTB? Without FTB and proper investment how we can achieve this critical technology properly? This is very shameful for India like country stills struggling for developing jet engine without any kind of aerospace testing facilities.

 

[Srinivas Nirmal Kumar Avula]

Without Kaveri Engine 100% success its very difficult to move forward Tejas1A program, complete IAF order, & export prospects for Tejas aircrafts
It's O.K. If we're Initially importing few engines form foreign countries.
But anything can happen in future due to rapidly changing geopolitics of the world. With this in mind the govt must use possible efforts within & outside India & last but not the least is money for success of Kaveri Engine project.
I have no doubt all Impossible will be possible, with the backup of Prime Minister Modiji & 1.4 billion Indians support behind the project.

 

[FIDA INDIA]

Where is our own FTB? Without FTB and proper investment how we can achieve this critical technology properly? This is very shameful for India like country stills struggling for developing jet engine without any kind of aerospace testing facilities.

Is it feasible to have a test bed for one engine program? Must have many engine. The test bed should fly at least once a year.

 

[ASHOK CARROL]

The engine needs a reduction of approximately 200-230 kg in weight with the use of new lightweight alloys. In case DRDO, GTRE, and Mishra Dhatu Nigam are unable to do it on their own by employing titanium-aluminum alloys, carbon fibers, ceramics, and nickel alloys with blings, single-crystal blades, and the use of 3D designing of the engine and parts, and the use of 7th-gen CNC machines to cut time, consultancy from Safran, Eurojet 200, GE, or even Russians should be sought to produce a 55kN to 85-90kN engine. The high-altitude test facility and four-engined flying test bed need urgent acquisition for the five aircraft and engine programmes.

 

[Anupom]

Is it feasible to have a test bed for one engine program? Must have many engine. The test bed should fly at least once a year.

At least we don't have to rely on foreign countries for 20-30 years. We can reduce the developmental time and use them to R&D. Hope new engine deal with foreign partner will include this FTB facility also.