Why Kaveri Engine Still Isn't Powering Tejas Jet After 44 Years of R&D

The Kaveri engine, a project conceived in the 1980s to propel India's indigenous Light Combat Aircraft (LCA) Tejas, remains unavailable even after decades of development. A confluence of technical complexities, project management issues, and external constraints have hampered its progress.

Technological Challenges​

Thrust Deficiency and Weight Issues: The Kaveri engine consistently struggled to achieve the necessary thrust, falling short of the LCA's operational demands. Its weight also proved problematic, impacting the aircraft's overall performance. Efforts are underway to address these issues through material improvements and component optimization.

Reliability and Durability Concerns: The engine faced significant hurdles in maintaining reliability and durability, especially under the demanding high-altitude, high-temperature conditions required for combat aircraft. Critical components like turbine blades proved particularly vulnerable.

Materials and Manufacturing Limitations: India's limited capabilities in advanced materials technology and precision manufacturing further compounded the challenges. Developing high-temperature materials and producing complex components with the required precision proved daunting.

Testing and Validation Issues​

Lack of Testing Infrastructure: The absence of comprehensive testing facilities, especially for high-altitude conditions, hampered the engine's validation under operational scenarios, leading to delays and incomplete assessments.

Limited Iterative Testing: Budgetary constraints and inexperience restricted the number of iterative tests and refinements essential for perfecting the engine's design, slowing down the development process.

Project Management and Delays​

Overly Ambitious Goals: The Kaveri project's initial goals were arguably overambitious, given India's technological and industrial base at the time. The timeline was optimistic, and the complexities involved in developing a jet engine from scratch were likely underestimated.

Frequent Design Changes: The evolving design specifications for the Tejas aircraft necessitated constant modifications to the Kaveri engine, adding further delays to the project.

International Sanctions and Technology Denials​

Post-Pokhran Sanctions: International sanctions imposed after India's nuclear tests restricted access to critical technologies and materials, impacting the Kaveri engine development. Key technologies from Western countries became inaccessible.

Limited International Collaboration: Concerns over intellectual property and security limited collaborative opportunities with foreign entities, hindering India's acquisition of crucial know-how that could have expedited the engine's progress.

Funding and Resource Constraints​

Inconsistent Funding: The Kaveri project faced fluctuating funding throughout its lifecycle. Delays and cost overruns strained the budget, necessitating compromises in research and development activities.

Human Resource Challenges: A shortage of specialized professionals experienced in jet engine development posed challenges in attracting and retaining top engineering talent critical for such a complex undertaking.

Positive Developments​

Despite the setbacks, recent reports suggest progress.

Successful High-Altitude Testing (February 2023): The dry Kaveri engine successfully underwent high-altitude testing, demonstrating its capability to operate effectively in challenging environments.

Improved Thrust Output (Projected): With the integration of a new afterburner, the dry Kaveri engine is expected to produce thrust exceeding 80kN, potentially surpassing the F-404 engine currently used in the Tejas Mk1A.

Flat-Rated Engine Design: The Kaveri engine's flat-rated design allows it to maintain consistent performance regardless of ambient temperature or flight speed, making it well-suited for India's hot and humid climate.

Potential for Future Upgrades: The Kaveri engine project envisions the development of the Kaveri-2 engine, capable of generating thrust between 90-95kN. This enhanced power output could make it suitable for more advanced Tejas variants and other future combat aircraft.

Initial Flight Release Certification (Projected 2024): The dry Kaveri engine is expected to receive its Initial Flight Release (IFR) certification by 2024.

The Path Ahead​

India's pursuit of self-reliance in aero-engine technology is a long and complex journey. Overcoming these challenges necessitates sustained commitment, substantial investments in R&D and infrastructure, and strategic international collaborations.

While the Kaveri engine project has faced numerous hurdles, recent developments offer a glimmer of hope. If these efforts prove successful, India could finally achieve its goal of powering its indigenous fighter jets with a homegrown engine, marking a significant milestone in its aerospace capabilities.

 

[R. Singh]

Better Ink deal with Rolls Royce to upgrade Kaveri 2.0 engine to generate 90+KN thrust followed by joint development of 5th and 6th gen fighters engines as well as engine variant that power's F-35B fighter for our AMCA-N

 

[ravin]

Institutional and private partnership in technology development was not engaged effectively. It is nearly half a century!🤔 Core components of the aviation not receiving adequate or right leadership in developing critical tech.

 

[Anil Tiwari]

As an ex-IAF officers son all I can say is officers belonging to South India clamour for a Bangalore posting near to their retirement age. There they conveniently build a house, marry their daughters and settle their sons. The development of aero engines and Light Combat Aircraft (now called Tejas) can go on for ever and ever.

 

[ankitksinghal]

It is shame, Indians are copy cat and they don't have enough IQ to make things on their own. Our national foundation is based on corruption and society accepts it. It is root cause of all issues...

 

[TRK]

Kaveri is the Name of a river. Engine is fire. Both does not go together. Change the name Kaveri to Surya. It may work.

 

[parimal vaikuthray Pandya]

There was an old news of comments on inefficiency of IITs and IIM by famous scientists Sam pitroda and u r Rao. And two' scientists Kadir Khan and Santhanam reported to get politically motivated glorified of missile man Abdul Kalam who was inefficient to get the reality

 

[Kiran]

People here in comments don't understand, GE and Rolls Royce have been making jet engine decades before India designed Tejas.
These companies have gone through 100's of prototypes and thousands of designs before manufacturing the engine they do today. Indian scientists and research people are expected to skip all these steps and make latest technology best engine in their first attempt. They failed obviously.
Kaveri jet engine program should have been similar to Agni or other missile series. You start small and keep doing improvements in thrust, weight and reliability. With this approach, India would have had range of jet engines of varying thrusts and finally getting to world class or leading engine.

 

[Dhawan]

Taking up such a high tech project in 80s was necessary, but ambitious. Then we had a very poor industrial base, no ecosystem for innovation, very limited low tech labs. So slow progress is no surprise. With improvement in the manufacturing eco system now, we should see better progress

 

[jku123us]

The biggest problem with Indian politicians they don't understand the basics for gaining popularity they announce big schemes but don't fund properly which is the basic reason of most of the delays.
Not that indians are not capable of making great breakthroughs.
See even now we are not having proper testing facilities which is the basic for research. Whatever
I have made I have to test then only I can go ahead. Everytime I cannot carry the engine to Russia to test which is costlier and time consuming.

I think even one year at around 1990 the funding was only 1 crore (read in article)when you under fund these type of critical projects they say that the money goes to dustbin because most of the money will go for salaries and other things.
Recently I also read that the present manufacturing facility for tejas is only 8 per year if this is the case how will they fullfill the order
The government has not sanctioned for increasing the production. Now they are thinking about exports.
So 90 percent of the reason is government
And also there is demand for making a separate cadre (pay structures) for the research wing which not in place to retain staff due to which some talented people's move abroad.

 

[sishir]

It is more than a decade in development. We knew our constrain from the beginning both MOD , IAF and other entities. It would have been better to get an international engine maker to do a joint enterprises with Indian company. The needs for fighter engine are huge for India. So any international high grade manufacturer would have made good money and we would have got a right engines and produce Teha aircraft faster. At the same time the Indian engine could have taken it's own time to develop and demonstrate as a reliable engine for fighter aircraft.

 

[BHARAT'S RISE]

There are glimmers of hope definitely. Besides more fund allocation & other support measures, development of Kaveri engine, Indian government has been talking to both Safran and GE for transfer of technology!
While Kaveri would remain a long-term goal and would proceed parallelly with the technology transfer from GE / Safran, the US is trying to create a leverage against India, by delaying and putting obstacles in GE's proposed 80% transfer of technology.

 

[Prado]

This is the outcome of the policy that we have neglected manufacturing and R&D in our country. Moreover govt companies and research labs are incapable of doing these kind of high end research where a private company could have done better and provide results. Our DRDO is one of the white elephant. We need to make them accountable, they don't have fear of their jobs. as long as salary is credited every month they are not going to perform. China and India were almost in same position by 80es. But now we are atleast 25 yrs behind them in manufacturing and capabilities. Govt need to show more political will so that manufacturing and R&D get a massive thrust.

 

[Bachan Shastri]

China did lots of reverse engineering to determine suitable materials, did establishe
in-house testing facility and resolve determination to achieve success. We entrospect back our resources. Success will definitely come. Good luck.

 

[atuls1590]

Kaveri project needs sustained efforts and more funds to be successful. Failures do come and to learn from those failures and do necessary changes is a long process. So infuse more funds and let the engineers and scientists do mistakes and improve on those mistakes. It is the only way to get desired results.

 

[Kishore sarkar]

The key required for becoming self-reliance is the ability to understand the underlying science & thereafter to develop, design, manufacture a workable & quality product. Sad & unfortunately this ability is missing in us. We need to introspect & contemplate how to overcome & manage this shortcoming.

 

[aarkay]

Important to operationalise current Kaveri engine & leverage learnings to develop more powerful engine.

Resort to collaborations in specific core/ sub-technologies, where needed

Create testing infrastructure

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