Indian Defence

India’s Aero Engine Challenges: Tech, Strategy, and Struggles

The F414 engine is being integrated into aircraft developed in countries like South Korea, Sweden, and Türkiye, with South Korea being the only nation currently co-producing the engine alongside the US In recent years, the US-India defense partnership has grown significantly in both scope and depth. Successive administrations from both political parties have recognized India as a key defense partner, an integral member of the Quad alliance (comprising Australia, India, Japan, and the US), and a cornerstone of America’s Indo–Pacific strategy. However, any transfer of sensitive technology to India carries inherent risks that, while manageable, must be carefully addressed in future agreements.

United States continue producing the world’s best jet engines. Companies like Pratt & Whitney and General Electric manufacture highly efficient engines for both commercial and military aircraft, offering unmatched power and reliability compared to engines from other nations. 

Credit – GE Aerospace

Risks and Considerations Intellectual property laws matter little to America’s geopolitical rivals. In the mid-1940s, the Soviet Union purchased Rolls Royce jet engines from a financially struggling United Kingdom and then cloned them to power their first operational jet fighter, the MiG-15.

That aircraft–engine pairing was a match for America’s best fighters at the time, and MiG-15 pilots shot down a sizable number of US fighter, bomber, and attack aircraft during the Korean War.

Credit – Wikipedia

Additional Soviet engines were built on the foundation that Rolls Royce naively provided, and the generations of aircraft engines that followed have proven formidable enough that Russian fighter aircraft are now a staple of air forces across the world, including China’s and India’s. It was not long before Beijing followed the Soviet lead and began cloning its own jet engines from Russian models. However, pilfering the technology of others is no substitute for the decades of research development, test, and evaluation (RDT&E) required to match Western technology. 

Over the past seven years, the US Air Force has invested more than $4.2 billion to develop a next-generation motor through the Adaptive Engine Technology Program (AETP). The AETP’s revolutionary technology is proven to significantly increase the thrust, fuel efficiency, electrical power generation, and cooling capacity for engine components and, if fielded, would put the US several (more) decades ahead of its nearest engine-producing rival. Yet, the Air Force has chosen not to field that engine, which means that the AETP’s revolutionary technology, which powers the F-18 Super Hornet, is still among the most advanced operational fighter engines in the world. China and Russia would love to get their hands on the technology to replicate the design, engineering, and manufacturing processes and field that technology into their own fleets. Fighter jet engines are highly complex. The design and manufacturing processes associated with everything from the housing to the individual turbine blades have been refined through decades of development and the generations of engines that preceded the F414. 

Any technology transfer carries associated risks of falling into the wrong hands or being reverse engineered by an adversary. This is precisely why the US has been reluctant to share jet engine technology with any but its most trusted treaty allies. General Electric has expressed confidence in its safeguards, though the more advanced the technology being transferred, the greater the risk.  Methods for mitigating that risk include withholding the most technologically advanced elements, such as ceramic composite materials, and replacing them with previous generational elements. So why is this advanced fighter engine technology being considered for India now? After all, the US also has the option of selling India the engines without transferring the technology and putting sensitive intellectual property at risk. First, the deal would build on existing defense cooperation with India, generally, and jet engines, specifically, and India has a good track record of reliability and security. Second, it serves America’s geopolitical interests and its Indo–Pacific strategy to continue strengthening ties with India, enhancing India’s military capabilities and the defense-related linkages between India and the US Building on Existing Defense and Jet Engine Cooperation In 2010, India bought 99 F414 engines from the US for $650 million, with an option to add 49 more, and it has already received a handful of off the-shelf engines for prototype testing. Under the terms of the agreement, a portion of those engines would be manufactured in India and roughly 50 percent of the technology required to build it has already been approved for transfer. 

The engines will power India’s Tejas Light Combat Aircraft Mk II, a fighter that has faced repeated production delays. The Indian Air Force is targeting 2028 for Tejas Mk II induction and GE is now estimating engine delivery in 2026.

Upgraded, More Potent Tejas To Be Rolled
Tejas MK2 Render By Kuntal Biswas | Twitter @Kuntal__biswas

The new arrangement being considered by the US would bolster the original deal and involve transferring even more technology to enhance Indian manufacturing of the engine. The US government’s process for evaluating critical technology risk and risk mitigation is controlled by the Department of Commerce through its International Traffic in Arms Regulations (ITAR).

Once the ITAR package for the F414 engine has been completed, it will be reviewed by the Departments of Commerce, State, and Defense and each will have to give its approval before any additional transfer can take place.

Geopolitical Considerations 

Donald Trump, right, and Narendra Modi at the White House in June 2017.Photographer: Andrew Harrer/Bloomberg

India has been an important geopolitical partner for the US and is an emerging great power. India is now the world’s most populous country with the third-largest defense budget, following only the US and China. After virtually no defense relationship with the US in the 20th century, India has purchased more than $20 billion in arms from the US since 2008. In 2013, India became the first country to purchase and field the advanced Boeing P8 surveillance aircraft, ahead even of US treaty allies.

In recent years, India and the US have also signed several foundational military agreements that, among other things, allow the two countries to share encrypted communications and refuel each other’s ships at sea. Nevertheless, the transfer of jet engine technology to India would mark a substantial upgrade in the level of technology that America is willing to provide to New Delhi. 

The move carries benefits that could at least partially offset the risks associated with the transfer. The US government has repeatedly affirmed that India is a pillar of the Quad grouping, which remains central to America’s Indo–Pacific strategy. Perhaps more important, the US government has repeatedly affirmed that it is inherently in America’s national interest for India to emerge as a strong, sovereign, net provider of security in the Indian Ocean as it contends with a rising China, which still claims more than 90,000 square kilometers of Indian territory. In recent years, the Chinese–Indian border dispute has entered a volatile new stage, with violent clashes in 2020 producing the first casualties from border hostilities in 45 years.

The F414 engine technology transfer would expand on the already growing interoperability between US and Indian military systems. India is already operating US-made MQ-9B Sea Guardian drones and P-8I maritime patrol aircraft, allowing the seamless sharing of information. Furthermore, the transfer will address New Delhi’s long-standing request for jet engine technology, enhancing India’s defense industrial base and the development of a highly skilled workforce. It would also improve perceptions of the US as a reliable supplier of choice for advanced defense technology. Partly because the US cut off arms sales to India during the Cold War, favoring Indian rival Pakistan, New Delhi has had a long-standing defense relationship with Moscow, with Russian platforms comprising a majority of legacy Indian military hardware. New Delhi is currently accepting delivery of a $5 billion arms package that includes the purchase of five Russian S-400 air defense systems. India also operated Russian-leased nuclear submarines and Russian-origin aircraft carriers. Expanding the type and sophistication of the arms the US is willing to sell to India may elevate the US as an alternative to India’s traditional dependence on Russian hardware, particularly amid rising concerns about Russia’s strategic embrace of China, and growing questions about the quality, reliability, and capacity of a Russian defense industrial base increasingly strained by the Ukraine conflict. Indeed, in 2022 India announced that it will ground its entire fleet of Soviet-era MiG-21s by 2025 following a wave of fatal mishaps resulting from mechanical failures. New Delhi also recently scrapped a long-pending deal for Russian Mi-17 helicopters and “deferred” the acquisition of more MiG-29 and Sukhoi-30MKI Russian fighters.

India’s close and long-standing defense relationship with Russia nevertheless increases risks associated with technology transfer. As a measure of that relationship, India has repeatedly abstained from voting in the United Nations to condemn Russia’s invasion of Ukraine. However, those risks must be balanced by India’s relatively strong track record on nuclear safety and nonproliferation. More important, over the past two decades of defense and intelligence cooperation, India has demonstrated a level of professionalism and reliability. That is evident by the fact the US has felt confident enough to transfer to India advanced surveillance aircraft, transport aircraft, artillery, attack helicopters, and drones. It has shared with India sensitive real-time satellite imagery, and the two sides are able to exchange, and communicate over, advanced encryption equipment. India and the US are also collaborating on aircraft carrier technology and aspiring to co-develop and co-produce a new generation of drones.

Leaps of Faith Fighter engine deals are commercial transactions, not gifts, and US defense firms have benefitted from billions of dollars in arms sales to India. Nevertheless, the transfer of particularly sensitive technology, such as jet engines, is as much a geopolitical decision as it is a commercial decision. It would represent a statement of US trust in India and intent for the future of the relationship. The fact that only now, nearly 20 years after signing the first major defense partnership agreement in 2005, is the US considering such a technology transfer, demonstrates the sensitivity of the technology involved. Supporters of the deal, and of Indian–US relations more broadly, must be prepared to articulate how America benefits from such an arrangement. The US government has repeatedly stated that its relationship with India is not merely transactional and that the US government should not tie approval to any explicit quid pro quo. Nevertheless, if the US is expected to take a leap of faith in India, New Delhi should be receptive to creatively expanding defense cooperation in other arenas. Which form that expanded defense cooperation might take is an open question. One possibility is greater Indian–US cooperation on the Andaman and Nicobar Islands. The islands hold great geostrategic significance stretching north to south as a gateway to the Strait of Malacca, which connects the Indian Ocean to the South China Sea and Western Pacific. 

Under Prime Minister Narendra Modi, India has made a concerted effort to develop the long-neglected islands as a more substantial naval and military hub in the eastern Indian Ocean. Yet, just as America has long been reluctant to share jet engine technology with non-treaty allies, India has long resisted allowing outside powers access to the islands. 

That is beginning to change: In 2020, India allowed US military aircraft to refuel at a military base in the Andamans for the first time. The two countries can do much more in the eastern Indian Ocean to enhance their own security and advance their shared vision for a “free and open Indo–Pacific.” A Joint Maritime Domain Awareness Center in the islands could help to track the growing number of Chinese naval assets operating in the Indian Ocean. The islands could also host a new annual Indian–US combined air and naval exercise focused on anti-submarine warfare. Such initiatives would help to strengthen the logic for taking India–US defense ties to new heights in the eyes of any skeptical lawmakers.

Future Programs in Indian Aero Engines

  • Kaveri Engine Program
    • Originally part of the Light Combat Aircraft (LCA) Tejas project, the Kaveri engine was developed by the Gas Turbine Research Establishment (GTRE) under DRDO.
    • More funding – north of 2 billion USD as of 2024.  A reliable Joint-Venture partner willing to transfer all critical IP and Technology Transfer (if required)
    • State of the art test facilities in house (high-altitude, engine-test cells and other various dependent testing labs.
    • A flying testbed.
    • The future fleet of LCA Mk 1A and Mk 2, followed by AMCA, TEDBF, Ghatak UCAV – are looking hopeful for GTRE deliver its punch.
    • A visionary of a person in the DG-Aeronautical Cluster who will push the MoD with no hesitation to get the work done.
    • Though the engine has shown potential, it has yet to achieve the thrust levels and reliability required for deployment in combat aircraft.
  • Dry Kaveri for UAVs
    • A modified version of the Kaveri engine is being considered for powering unmanned aerial vehicles (UAVs). This “dry” engine omits afterburners, making it suitable for non-combat applications.  The DRDO aims to complete testing and integration of the Kaveri engine with Ghatak by 2026, marking a significant step towards enhancing India’s indigenous UAV capabilities.
  • AMCA Engine Development
    • The Advanced Medium Combat Aircraft (AMCA), India’s 5th-generation stealth fighter project, requires an indigenous engine capable of high performance and stealth.
    • Efforts are underway to develop an engine with at least 110 kN thrust for the AMCA, potentially through international collaboration.  40 jets (or two squadrons) of AMCA Mk-1s powered by an American GE F-414 engine will be inducted into the Indian Air Force (IAF) by 2036s.
  • High-Altitude and Helicopter Engine Development in India:
    • India’s Objective: India is actively working on enhancing its capabilities for engines suited for high-altitude operations and helicopters. This is key to strengthening its defense forces, especially in regions like the Himalayas, where terrain and altitude pose significant challenges to aviation.
  • SAFHAL – The Joint Venture:
    • SAFHAL (a collaboration between Safran Helicopter Engines and Hindustan Aeronautics Limited, or HAL) plays a pivotal role. This joint venture focuses on the design, development, production, and support of next-generation helicopter engines in India, contributing to the nation’s Aatmanirbharta (self-reliance) in this critical area. It’s a major milestone in India’s effort to reduce reliance on foreign suppliers for military and civilian helicopter engines.
  • Indian Multi-Role Helicopter (IMRH) and DBMRH:
    • HAL’s IMRH, a 13-ton helicopter, and the DBMRH (Deck-Based Multi-Role Helicopter) designed for the Indian Navy, are two significant projects. These helicopters are designed to meet various operational needs of India’s armed forces, such as search-and-rescue, troop transport, and maritime defense. These helicopters need engines capable of handling challenging environments, particularly at high altitudes or extreme temperatures.
    • There’s also a plan for these helicopters to extend into the civilian market in areas like offshore operations, utility transport, and VVIP transport, showing a wide range of potential uses for these platforms.
  • Safran’s Role:
    • Safran Helicopter Engines has long been a trusted partner for HAL, providing engines like the Artouste, Shakti, and their variants for the Cheetah, Chetak, ALH (Advanced Light Helicopter), LCH (Light Combat Helicopter), and LUH (Light Utility Helicopter).
    • This collaboration is being elevated through the design and development of new-generation helicopter engines for medium-lift helicopters, which will be crucial for India’s defense modernization.

These developments are aligned with India’s broader defense and aerospace strategy, focusing on self-sufficiency and technological advancements to strengthen national security and defense capabilities. The synergy between HAL and Safran, combined with the development of advanced helicopter engines, marks a pivotal moment for India’s aerospace sector.

Why Indian Aero Engine Programs Face Challenges?

Technological Complexity

  • Jet engine development is one of the most challenging engineering tasks, requiring expertise in aerodynamics, materials science, and thermodynamics.
  • India lacks extensive experience in developing high-thrust, high-performance engines.

Material Science Limitations

  • Advanced materials like single-crystal turbine blades and thermal barrier coatings are critical for jet engines. India has struggled to indigenously produce these at the required quality and scale.

Insufficient Funding and Long Timelines

  • Aero engine programs require sustained funding over decades. Budget constraints and shifting priorities often slow progress.

Lack of Collaboration

  • Historically, India pursued a largely indigenous path, which limited access to global expertise. While this is changing with partnerships like Safran, past isolation slowed progress.

Test and Validation Challenges

  • Developing and certifying engines requires extensive testing under varied conditions. India’s test facilities are limited compared to leading nations.

Dependency on Imports

  • Due to delays and underperformance, India has had to rely on foreign engines (e.g., GE engines for LCA Tejas), creating a cycle where indigenous development struggles to catch up.

Program Management Issues

  • Bureaucratic delays, inefficiencies, and a lack of coordination between stakeholders have hampered progress.

How to Address These Challenges?

Enhanced Funding and Long-Term Vision

  • Allocate consistent and increased funding for engine R&D with a clear roadmap.
  • Encourage public-private partnerships to leverage industrial expertise.

International Collaboration

  • Expand collaborations with global leaders in engine technology for knowledge transfer and co-development.

Strengthening Material Science Capabilities

  • Invest in R&D for advanced materials and establish manufacturing facilities to produce them indigenously.

Improved Testing Infrastructure

  • Build state-of-the-art facilities for high-altitude, stress, and endurance testing.

Skill Development

  • Train a new generation of aerospace engineers and scientists with a focus on engine technology.

Focus on Incremental Success

  • Start with achievable goals like engines for UAVs and helicopters before progressing to high-thrust engines for fighter aircraft.

Sheikh Akhter

Warfare & Defense Systems l Military Equipment Intelligence | OSINT I Content, Insights & Strategy | Leadership | Solutions | Policy | A&D Consulting

Leave a Reply

Your email address will not be published. Required fields are marked *

Related Articles

Back to top button
Translate »