HAL's Tejas Mk1A Airframe Production on Track to Meet Annual Target of 16, Utilizing Older Engines for Testing Amidst Delays

Hindustan Aeronautics Limited (HAL) is forging ahead with the production of the Tejas Mk1A light combat aircraft despite facing setbacks due to delays in the supply of F-404 engines from General Electric (GE).

Undeterred by this hurdle, HAL has already completed 14 airframes ready for final assembly, awaiting the resumption of engine deliveries. This proactive approach underscores HAL's commitment to meeting the delivery schedule of 83 Tejas Mk1A fighters to the Indian Air Force (IAF) by 2028-29, as per the contract.

To maintain momentum and ensure timely delivery, HAL is implementing a strategic plan. The company is utilizing older F-404 engines, likely from existing Tejas Mk1 inventories or reserves, to conduct rigorous testing on the completed airframes. This allows HAL to ensure the aircraft meet operational readiness and quality standards without being hindered by the engine supply chain disruption.

Furthermore, HAL is gearing up to achieve an ambitious production rate of 16 Tejas Mk1A airframes annually, starting in 2025-26. This significant increase in capacity will be facilitated by ongoing upgrades to the production line, including investments in automation and advanced manufacturing facilities. These measures demonstrate HAL's commitment to establishing a robust and efficient production ecosystem for the Tejas program.

The Tejas Mk1A order, placed by the IAF in 2021, represents India's largest indigenous defence contract to date. HAL is under considerable pressure to meet the delivery deadlines for this vital upgrade over previous Tejas variants.

The aircraft boasts significant improvements over its predecessors, including enhanced avionics, advanced radar capabilities, upgraded electronic warfare systems, and reduced maintenance costs. By maintaining production despite challenges, HAL is not only adhering to the contractual timeline but also reinforcing India's "Atmanirbhar Bharat" (self-reliant India) initiative, which aims to reduce dependence on foreign suppliers in critical sectors.

The delay in the F-404 engine supply is attributed to global supply chain disruptions impacting the aerospace industry worldwide. However, HAL remains optimistic, citing assurances from GE that engine deliveries will resume shortly. The Indian government is closely monitoring the situation, recognizing the Tejas Mk1A's crucial role in maintaining the IAF's squadron strength and operational readiness.

This strategic approach to production, coupled with a focus on indigenous capabilities, highlights India's growing self-reliance in defence manufacturing and its determination to overcome global challenges in pursuit of its national security objectives.

 

[Sudha]

A big mistake. HAL should be ready with the design for an alternative engine to be powering tejasmk1a. All these delays strongly suggests of armtwisting by US. More than a year delay by GE suggests armtwisting by US and Trump is unpredictable.

 

[Mithu Roy]

GE should deliver F-404 Engines timely else Sukhoi MKI line will become live like ak 203.
plus Russians are developing top of the line commercial jets which can be converted into transport planes in future

 

[GMR]

Good job, if HAL is telling the truth. Also, for the 2nd trench to be ordered, HAL & MOD should seek design changes in the jet to accomodate alternate engine, should current situation persists.

 

[Akshat]

A big mistake. HAL should be ready with the design for an alternative engine to be powering tejasmk1a. All these delays strongly suggests of armtwisting by US. More than a year delay by GE suggests armtwisting by US and Trump is unpredictable.

I can’t remember such vicious hatred when Russia delayed S400 deliveries (or Vikramaditya or refused to transfer tech for Ka226). None of that was arm twisting. Nor are the delays from our very own OFB and HAL. Why is this reserved only and only for US? You think they just can’t have a 10 month delay bro?

P.S.
1. I hope you won’t start calling me a US agent now.
2. HAL hasn’t even delivered the trainers yet. They haven’t delivered the first mk1a which has an engine. So take this news with a pinch of salt as no sources are mentioned here.

 

[Shiva]

There is no surprise HAL taking these steps.

These are resilient steps HAL/DRDO were taking from decades, despite taking blames from public/media/foreign vendors for the delay due to delay in supply from foreign component suppliers.

However, another resilient step is indeed needed.
Either with CCS approval or without it, HAL has to start this as well.

HAL has to learn and have expertise in replacing the engine with AL-31FP engine along with changing internal fuel tank by 100kg. These two changes defintely require design changes and little changes in the dimension of airframes or other components and repositioining of few components.
But the ability to make these changes, if possible without altering complex components , is a strategic asset needed for the country.

It is very clear from Russia-Ukraine conflict that, during critical time, any products that involve multiple countries, especially when it is made by US companies, will face so much of delays, to an extent that, you cannot replace the components during the war time. If you get those components after the end of the war, then it is simply useless.
This engine is a critical component and India cannot afford waiting for it during war time.
India has the capability to create AL-31FP engines quicly at rapid pace.
Also, fundamental studies showed that,
replacing GE engines with AL-31FP engine along with increasing internal fuel tank size by 100kg or so, will alter the product with below changes.
1 . range will increase. 2 . net throughput increases 3. maneurability will increase.
These three are critical factors for any aircraft during war time.
So, the changed product will definitely do all the activities what these products (Tejas/AMCA) will do with GE products.

Also, this technology know-how to be able to alter design quickly to replace engine as well as increasing internal fuel tank size together withi a quick succession, will pave a way, in future to replace the engines with better engines like next variants of AL-FP engines, other heavy engines like Kaveri, or any other engines produced from France/Europe/US/UK cooperation.

This technologg know-how also paves a way, for India , to develop engines first in bulk production and once engines are available, then can design products , either aircraft/unmmanned ones/any other flying things using the engines.

This will also pave a way , for a reserach on bulk production of engines , with little variations in performance. Because these variations of the engine performance can be circumvented with additional increase in fuel size and little reduction in weapon capacity there by producing a product which will do the same job, may be little less number of weapons, but those weapons will do same work and because of the abilty to bulk produce engines, we can have a way to bulk produce aircrafts etc.

So, this is an essential future direction HAL should work upon, in my opinion.
PLease discuss with experts and suggest to be ready with acquring ability to make design changes, espeically abilit yto replace one engine iwth other and increasing internal fuel tank and adjusting components a bit without changing critical components (whose changes could be complex design changes) to get a product without bothering much how will be its performance. Just focus on three critical factors (range, maneurability, net thrust)

 

[Praveen]

HAL has to learn and have expertise in replacing the engine with AL-31FP engine along with changing internal fuel tank by 100kg. These two changes defintely require design changes and little changes in the dimension of airframes or other components and repositioining of few components.
But the ability to make these changes, if possible without altering complex components , is a strategic asset needed for the country.

Bro What you said here is wrong there is a huge difference in dimensions of both engines, so al-31fp can't be fitted anyway. But instead we can fit ej-200 engine used in eurofighter typhoon. It offers 60KN dry thrust compared to 48KN of f-404 and 90KN of afterburning thrust compared to 84KN of F-404 offered to us. EJ-200 is both small , lightweight by 100 kilos, and more fuel efficient. I think the main reason why this engine is not selected is because it's gearbox is supplied by German company MTU which have given us the same engine for Arjun tank before. Before German government will block even small arms sales to us, so it is not surprising that this engine will not be selected.

 

[Utopian]

We should take this as a mission of national pride.. USA is known for its Decit. Never forget that Nikson was master mind of 1965 attack on india by supplying pattent tank to india. USA stood with Pakistan in 1971 as well . USA can't be trusted. It has betrayed it's friends many times in past. We are paying them, but don't trust USA or GE.

 

[MacMohan]

Hal to be awarded for such active step. After engine arrives next episode will start . Till then enjoy the movie

 

[Andy13]

Even if GE supplies 2 pm from March, they will end up completing the 83 order by end of 28. Better look for alternative engines and change design to Mk1B for the second order of 97 till then.

 

[Prit]

I can’t remember such vicious hatred when Russia delayed S400 deliveries (or Vikramaditya or refused to transfer tech for Ka226). None of that was arm twisting. Nor are the delays from our very own OFB and HAL. Why is this reserved only and only for US? You think they just can’t have a 10 month delay bro?

P.S.
1. I hope you won’t start calling me a US agent now.
2. HAL hasn’t even delivered the trainers yet. They haven’t delivered the first mk1a which has an engine. So take this news with a pinch of salt as no sources are mentioned here.

Work on trainers came into focus after FOC work of mk1 ie 2019 as they needed to be FOC variant. It was designed, reviewed, verified and production started after delivery of Mk1 aircrafts only on 1 single production line as focus shifted to Mk1A. The delivery should complete by this financial year according to current schedule.

 

[ramdas]

They have some spares of F404 engines with these HAL could have developed the MKIA fighter trainers, but not done.

 

[Prit]

They have some spares of F404 engines with these HAL could have developed the MKIA fighter trainers, but not done.

They were designed, reviewed, verified and their production started within 4 years! These iterative changes may seem small but whole aircraft has to undergo through all the regulations in place. That takes time. Sure private companies could have done better. I'm hopeful by the time of Mk2, someone like TATA should be ready.

 

[Kira]

As I have stated multiple times beforehand, HAL can always manufacture all the airframes without the engines just fine, there indeed would be a delay for the IAF,but they don't have halt production just because of dearth of any engines.

 

[Anurag]

I can’t remember such vicious hatred when Russia delayed S400 deliveries (or Vikramaditya or refused to transfer tech for Ka226). None of that was arm twisting. Nor are the delays from our very own OFB and HAL. Why is this reserved only and only for US? You think they just can’t have a 10 month delay bro?

P.S.
1. I hope you won’t start calling me a US agent now.
2. HAL hasn’t even delivered the trainers yet. They haven’t delivered the first mk1a which has an engine. So take this news with a pinch of salt as no sources are mentioned here.

Well they supplied us enough before delivery gets delayed and it's not complete Russian fault we are also not able to pay them!! So it was at a time mutual delay from both end!!
ka-226 delivery was never takes off it was on negotiation and end with the negotiation so what is this drama!!
well if you believe US aerospace giant Ge is with in the league of hal that can delay for 2 years then fine if you have just complains for Indian companies then why you feel only hatred towards west!!

Where is the engines for the trainer too many!! How they supposed to deliver it without the engines!! Is IAF supposed to fly them without engines??

 

[Indra Roy Sharma]

India is trying to get into design and development of the substitute for GE 404 engine. But HAL would have taken care of such eventuality….

 

[Anant]

Well they supplied us enough before delivery gets delayed and it's not complete Russian fault we are also not able to pay them!! So it was at a time mutual delay from both end!!
ka-226 delivery was never takes off it was on negotiation and end with the negotiation so what is this drama!!
well if you believe US aerospace giant Ge is with in the league of hal that can delay for 2 years then fine if you have just complains for Indian companies then why you feel only hatred towards west!!

Where is the engines for the trainer too many!! How they supposed to deliver it without the engines!! Is IAF supposed to fly them without engines??

Boss, the engines for the trainers already exist. We have had the first order of 75 engines delivered completely.

From this, let's remove engines for the 2 Technology Demonstrators, 6 Prototypes, 3 Naval Prototypes, and 8 LSP aircraft. That leaves 56 engines. Let's further remove the engine used on the first Tejas Mk 1A, leaving us with 55.

These 55 engines were to be used on 40 aircraft (the original Tejas Mk 1 order comprising 32 fighters and 8 trainers). Of these, the IAF has received 34 jets to date (32 fighters plus 2 trainers), with 33 of those operational.

That leaves 21 engines. Even if a third of those were used up during testing and are no longer, that still leaves us with 14 engines. The IAF would be maintaining a spares pool, but with such a small fleet, the pool would also be commensurately small.

Therefore, as you can see, the engines do exist, but the trainers are yet to be delivered. That is HAL's fault.

 

[Anant]

GE should deliver F-404 Engines timely else Sukhoi MKI line will become live like ak 203.
plus Russians are developing top of the line commercial jets which can be converted into transport planes in future

Russia isn't developing "top of the line commercial jets". The MC-21 and Tu-204/Tu-214 are essentially generic passenger liners. If anything, both of them are actively worse on multiple aspects than the A320neo and 737 MAX families. As for the SSJ 100, well, it is just about comparable to the E-Jet family.

Oh, and those aren't getting converted to transport planes. Atleast no more than you can convert other passenger liners to that role.

 

[Akshat]

Well they supplied us enough before delivery gets delayed and it's not complete Russian fault we are also not able to pay them!! So it was at a time mutual delay from both end!!
ka-226 delivery was never takes off it was on negotiation and end with the negotiation so what is this drama!!
well if you believe US aerospace giant Ge is with in the league of hal that can delay for 2 years then fine if you have just complains for Indian companies then why you feel only hatred towards west!!

Where is the engines for the trainer too many!! How they supposed to deliver it without the engines!! Is IAF supposed to fly them without engines??

The engines for the trainers were supplied even before 2020. I am talking about the original 8 trainers. Only 5 of those have been delivered. So HAL is nowhere near ready to deliver mk1a even with the engines.

Russia delayed the start of the delivery of S400 and that was after we paid them. We had a 6month delay in payment due to Catsa but even after that massive delays happened in S400. Then the war came.

 

[kurtwallis wallis]

very soon HAL gets sanctioned by USA for Russia parts sales and so no more GE engines deliveries at all!!

 

[Anurag]

Boss, the engines for the trainers already exist. We have had the first order of 75 engines delivered completely.

From this, let's remove engines for the 2 Technology Demonstrators, 6 Prototypes, 3 Naval Prototypes, and 8 LSP aircraft. That leaves 56 engines. Let's further remove the engine used on the first Tejas Mk 1A, leaving us with 55.

These 55 engines were to be used on 40 aircraft (the original Tejas Mk 1 order comprising 32 fighters and 8 trainers). Of these, the IAF has received 34 jets to date (32 fighters plus 2 trainers), with 33 of those operational.

That leaves 21 engines. Even if a third of those were used up during testing and are no longer, that still leaves us with 14 engines. The IAF would be maintaining a spares pool, but with such a small fleet, the pool would also be commensurately small.

Therefore, as you can see, the engines do exist, but the trainers are yet to be delivered. That is HAL's fault.

Let's calculate it 2 TD aircraft, 6 prototypes, 3 Naval prototype, 8 Lsp, so total 19 engines used so far while for data collection and further testing few engines used let's say 7 so total 26, now comes to 32 fighter + 5 trainers deliver!! So total 63 engines and now Mk1a that is flying so total number is 64 that left engines 10-11 within the IAF and for operational needs they need it for standby!!

So yeah IAF are in tight position.

 

[Andy]

At 2 engines per month, starting March, we will get all 83 engines by Aug 28. Either GE gives us water tight guarantees to supply 3 p.m. by 2026, or, we can use this time to redesign Mk1B to fit another available engine by then.

 

[Anurag]

The engines for the trainers were supplied even before 2020. I am talking about the original 8 trainers. Only 5 of those have been delivered. So HAL is nowhere near ready to deliver mk1a even with the engines.

Russia delayed the start of the delivery of S400 and that was after we paid them. We had a 6month delay in payment due to Catsa but even after that massive delays happened in S400. Then the war came.

Well initial delay was due to we are not able to make payments so it took time to finalize the payment method!! Starting of war was again a issue we are not able to further payment them due to payment method!! But later it was the war that delayed it by a a more than a year...so no one side can claimed only one side fault here!!

 

[Anant]

Let's calculate it 2 TD aircraft, 6 prototypes, 3 Naval prototype, 8 Lsp, so total 19 engines used so far while for data collection and further testing few engines used let's say 7 so total 26, now comes to 32 fighter + 5 trainers deliver!! So total 63 engines and now Mk1a that is flying so total number is 64 that left engines 10-11 within the IAF and for operational needs they need it for standby!!

So yeah IAF are in tight position.

Considering the fact that most of the Tejas engines are presently new, the IAF would only need spare replacement engines (that is, engines used to replace faulty engines). Age replacement engines (that is, engines required to replace older engines that are at the end of their life) aren't required. You don't need 11 engines in the former category for 35-ish aircraft.

In any case, that still leaves a few engines that HAL could have used. Still, let's keep that aside for a moment. If HAL has atleast one engine in a Tejas Mk 1A, why is that aircraft delayed by over 7 months now? It was supposed to be delivered in March, and November has now begun.