In a strategic move to bolster the Indian Air Force's (IAF) combat fleet, Hindustan Aeronautics Limited (HAL) is preparing to procure 113 additional F404-GE-IN20 engines from American firm General Electric.
This new order will supplement 99 units contracted in 2021 and an earlier 75 acquired since the program's inception.
The procurement solidifies the F404's position as the core powerplant for India's indigenous Light Combat Aircraft (LCA) Tejas fleet, ensuring its operational readiness for the next two to four decades while the nation pursues a long-term indigenous engine solution under the Atmanirbhar Bharat (self-reliant India) initiative.
The GE F404-GE-IN20, a turbofan engine capable of producing 84 kilonewtons (kN) of thrust with an afterburner, has been integral to the Tejas program since the late 1990s.
It was selected for its proven track record, reliability, and high thrust-to-weight ratio, famously powering aircraft like the American F/A-18 Hornet.
This engine currently powers the 40 Tejas Mk1 aircraft in service with the IAF and is being fitted onto the 83 advanced Tejas Mk1A jets.
The latest order, estimated to be valued at around $1 billion, is crucial for sustaining the production line for a planned fleet of 180 Mk1A jets, which includes 97 additional aircraft approved by the Defence Acquisition Council recently.
Integration of these engines will take place at HAL's facility in Nashik, where the Tejas airframes are assembled.
While a 2021 agreement facilitates the partial local manufacturing of some engine components, increasing indigenous content to 18%, India remains dependent on GE's global supply chain for critical hot-section parts like turbine blades.
The F404 was chosen over competitors such as the Eurojet EJ200 primarily for its technological maturity and lower integration risks, making it highly compatible with the Tejas's lightweight design, which is optimized for agility in high-altitude environments.
Each engine has an operational life of 2,000 to 4,000 flight hours, after which it requires a major overhaul or replacement, ensuring a sustained demand.
The F404 engine has demonstrated outstanding reliability in IAF service, with no engine-related failures reported since the Tejas was inducted in 2016.
This performance is vital for the significantly upgraded Tejas Mk1A, which is equipped with advanced systems like an AESA radar, modern avionics, and indigenous weapons such as the Astra air-to-air missile.
Looking ahead, India's Gas Turbine Research Establishment (GTRE) is collaborating with French defence firm Safran to overcome delays and revive the indigenous Kaveri engine project.
This partnership aims to develop a more powerful 90-110 kN thrust engine to power future aircraft like the Tejas Mk2 and the Advanced Medium Combat Aircraft (AMCA).
However, retrofitting the existing Tejas Mk1 and Mk1A fleet with a new engine is considered economically and technically unfeasible due to the extensive redesign and recertification required.
This continued reliance on the F404 engine represents a practical approach, balancing immediate operational requirements with long-term strategic goals.
The cumulative order of 287 engines will create a substantial inventory to support a fleet of over 220 Tejas aircraft projected to be in service by 2035. This is a critical step in addressing the IAF's pressing shortfall of fighter squadrons, which currently stands at 31 against a sanctioned strength of 42.
Furthermore, this large-scale procurement positions HAL to potentially establish a regional Maintenance, Repair, and Overhaul (MRO) facility for F404 engines, with discussions underway for licensed production in Bengaluru, which would further enhance India's aerospace and defence self-reliance.
