Comprehensive Design Review Accepted by IAF
India has been making concerted attempts to boost the capability of its armed forces as the country faces what is seen as two-front war threats from China and Pakistan.
While the more superior fighters in the Indian Air Force (IAF) fleet were flying around, over and near the Eastern Ladakh sectors, the light combat planes had assumed the role of a watchdog against Pakistan along the Western region.
India has been attempting to develop a variety of indigenous technology and weapon systems in order to increase defense sector self-reliance, especially for its Light Combat Aircraft (LCA) Tejas.
Order for 83 LCAs
In February 2021, HAL was awarded the contract to manufacture 83 LCA for the Indian Air Force (IAF) at an estimated cost of Rs 48,000 crore at the 13th edition of Aero India in Bengaluru, bringing the total number of LCA versions ordered to 123. The 40 LCAs that the IAF has already ordered are in the initial operational clearance (IOC) and advanced operational clearance (FOC) variants.
Deliveries to the IAF will begin in 2023 and end in 2024. The indigenous fighter will be outfitted with a locally-developed flight control computer and an air data computer, both of which will be provided by BEL under this deal. Defence Research & Development Organisation (DRDO) and Bengaluru’s Aeronautical Development Agency (ADA) have collaborated to develop both of these systems.
The LCA Mk-1A will have a number of enhancements over the FOC aircraft, making it the most advanced LCA variant to date.
The Mk-1A variant includes digital radar warning receivers, external self-protection jammer pods, AESA radar, enhanced beyond-visual-range (BVR) missiles, and greatly better maintainability. The indigenous component of the fighter is estimated to be around 60%, compared to 50% in earlier models.
On 16 December 2021, Hindustan Aeronautics Limited (HAL) signed a a five-year deal with Bharat Electronics Limited for the development and supply of 20 types of systems for the Tejas Mk1A light combat aircraft (LCA) program. The deal, which runs from 2023 to 2028, entails supplying crucial avionics Line Replaceable Units (LRUs), Flight Control Computers, and Night Flying LRUs in what is called the biggest ever order that the state-run company has placed on any Indian company boosting ‘Atmanirbhar Bharat’ campaign.
After completing the requisite design efforts, HAL has set a March 2022 timeline for the first flight of the LCA Mk-1A fighter, according to HAL chairman R Madhavan.
The LCA Tejas and its two variants in the pipeline have become the flag-bearers of India’s indigenous defense manufacturing. The new HAL contract is expected to not only give the requisite push to self-reliance but also boost the capability of the Tejas which is now being pitched to friendly countries.
Indigenous AESA Radar
The development of a indigenous AESA radar, which will be installed in the Tejas, is a big step forward and is aimed at creating a balance of power with China.
These AESA radars will be installed in all 83 Mk1A Tejas Aircraft which will boost its capability significantly. These radars, like the current avionic systems, are also largely indigenous with about 95% local component.
The AESA radar includes an electronic warfare (EW) suite with a jammer, the Combined Interrogator and Transponder (CIT) – an IFF plus system – and a digital map generator.
Hammer Missiles
Additionally, India is also procuring Highly Agile Modular Munition Extended Range (HAMMER) missiles from France to integrate them with the LCA Tejas aircraft after its success with the Rafales.
They are being procured under the emergency route granted to the military in the backdrop of continuing Chinese aggression. These missiles are expected to enhance the firepower of these LCAs and allow them to strike bunker targets deep inside the enemy territory.
Tejas Mark 2 Design Cleared
The LCA) is now evolving from its current, single-engine, Mark 1 avatar to a more sophisticated, twin-engine, fifth-generation fighter. On 15 November 2021, Deputy Chief of Air Staff (DCAS), Air Marshal Narmdeshwar Tiwari, accepted the comprehensive design review (CDR) of the LCA Mark 2.
A CDR is a multi-discipline, technical review that is a critical step in designing an aircraft. It involves examining the air frame design to ascertain that the aircraft is ready for fabrication and testing and it would achieve its stipulated performance within cost, schedule and risk.
The IAF’s acceptance of the CDR clears the way for HAL to start releasing drawings for fabricating the Mark 2’s first prototype.
Alongside building the Mark 2 prototype, HAL and the ADA – the DRDO agency that oversees the entire Tejas programme – must still resolve a few glitches that remain in the Mark 1 fighter; and also complete delivery of the IAF’s order of 40 Mark 1 (two squadrons) and 83 Mark 1A (four squadrons).
Status of the Indigenous Fighter Project
The first two Mark 1 squadrons are already operational in Sulur, near Coimbatore. Each of them is authorized 20 fighters, including four twin-seat trainers. The trainers’ specifications were finalised late, so they will be built along with the 10 trainers of the four Mark 1A squadrons.
The IAF has cleared the “FOC for the Mark I fighter, even though that involved granting 25 concessions – or performance shortfalls from the IAF’s specified requirements. HAL, ADA and the IAF are working together to resolve these shortfalls.
Issues Resolved
Issues which have already been resolved include equipping the Tejas to re-fuel in-flight, by day or night. This was proved by refuelling into internal fuel tanks or external drop tanks, from IL-78 refuellers or from Sukhoi-30MKI acting as “buddy refuellers.
The capability to monitor fuel levels in the Tejas through an integrated Environmental Control and Fuel Management (ECFM) system has also been resolved.
The Gasha 23 mm gun has been integrated into Tejas Mk 1 but live firing was pending. The same has also been done.
The indigenous Astra air-to-air missile and Safran’s HAMMER air-to-ground bomb are waiting to be integrated onto the Tejas. HAL is doing the mechanical and electrical integration, while the DRDO is handling the software and the weapons algorithm.
Fatigue tests remain to establish the fighter’s service life span. These tests involve taking an aircraft from the production line and subjecting it to repetitive loading. As more and more hours are logged and the data accumulates, the manufacturer increases the designated life-span proportionately. It takes about nine years of testing to establish 3,000 hours of service life.
The digital map generator, designed by HAL’s Mission and Combat Systems R&D Centre (MCSR&DC), carries the complete map data of the country and neighbouring areas. Depending upon the Tejas’ mission, it extracts the digitised map of the current mission area and transfers it to the pilots’ display, where he can easily access it.
HAL is also integrating the Advanced Short Range Air-to-Air Missile (ASRAAM) onto the Mark 1A. The ASRAAM, which has a range of 60-70 kms was bought by the IAF from MBDA UK, for upgrading its Jaguar fighters. Now each Tejas too will carry two of these missiles on its outboard stations.
Another modification involves reshaping the cockpit floor to enable bigger pilots – with shoe size up to 10, which includes 95 per cent of all IAF pilots – to fit into the cockpit and fly the aircraft comfortably.
What Will the Tejas LCA Mk 2 be Like?
The Tejas Mark 2 is will be significantly larger and more capable than the Mk 1, with a higher thrust engine and a 1.5-metre increase in length. While there is no change in the size of the wings, they have been pushed outwards, effectively increasing the fighter’s wingspan by 300 mm.
Ahead of the wings, a canard has been added, creating a resemblance with contemporary fighters such as the Rafale, Eurofighter or the Sukhoi-30MKI. The canard provides an additional control surface that creates a vortex, increasing the lifting capability and agility of the aircraft.
The Mark 2 has increased payload capacity to integrate more weapons and sensors. It will carry the indigenous Astra Mark 1 and Mark 2 missiles, Rudram anti-radiation missiles, developed by the DRDO’s Defence R&D Laboratory (DRDL) (tested on 9 October).
DRDO is developing the Tara (high speed, low drag) bomb that is mounted on the pylons. It will also have the option of carrying laser guided bombs (LGBs), fitted with laser-guidance kits. Mark 2 may be integrated with the SCALP missile that has been procured along with the Rafale fighters.
Tejas Mark 2 will have 11 hard points, including one on each wingtip for the ASRAAM air-to-air missile. There will be three under-wing pylons on each side, one wet station on each side for fuel drop tanks, while the other three hard points are for long-range missiles such as the Astra and Rudram.
Fitted with significantly more powerful General Electric (GE) F-414 engine, the Mark 2 would have its internals rearranged, to make them more accessible and maintenance friendly. Line replacement units will be optimally rearranged to improve space utilisation, accessibility and make maintenance easier and reduce turn-around time.
Aeroengines
HAL had signed a $716 million deal with American company GE Aviation earlier this year for 99 F404 aircraft engines and related services to power the indigenous Tejas LCA Mk-1A. On top of that, it is now building its own indigenous engine that is expected to power its Tejas variants as well as its Advanced Medium Combat Aircraft (AMCA) aircraft.
The current GE F-404 power pack will be replaced with F-414, whose peak thrust of 83 KiloNewtons (kN) is considered inadequate. The GE F-414 engine will deliver 98 kN of peak power. The new engine will enable the Mark 2 to take off with a maximum all-up weight of 16.5 tonnes, which will include the 10-tonne weight of the fighter and 6.5 tonnes of external payload.
The Tejas Mark 2 can carry 3.5 tonnes of fuel in external drop tanks, in addition to 3.3 tonnes in its internal fuel tanks, while still carrying three tonnes of weapons and sensors.
