AMITY INSTITUTE OF SPACE SCIENCE AND TECHNOLOGY

Sector-126, Noida, Uttar Pradesh-201313, INDIA

An INTERNSHIP REPORT ON

“ STUDY OF LCA TEJAS AIR CRAFT”

Submitted in partial fulfillment of the requirement for the award of the Degree of Bachelor of Technology in

AEROSPACE ENGINEERING and Master of Engineering in AVIONICS for the academic year

2016-2017

Submitted by :

NAIK SAMAR P. VISHESH MANAV

(A4717213004) (A4717213008)

SUMMER INTERNSHIP CARRIED OUT AT

LCA TEJAS Division, HAL, Bangalore

Under the guidance of

SHRI. MANOHAR PRASAD Ms. PRIYANKA K. MR. SENTHIL KUMAR

SM(EQ & FA) AE LCA-LSP CHIEF ( FCS)

LCA TEJAS Division, HAL LCA TEJAS Division, HAL LCA TEJAS Division, HAL

ACKNOWLEDGEMENT

It is with great satisfaction and euphoria that we are submitting the internship report on “STUDY OF LCA TEJAS AIR CRAFT” which we have completed as a part of curriculum of our university.

I would extremely thank our Principal and Head of Institution of Aerospace and Avionics Engineering Prof. M. Prasad, who has always been a great source of inspiration and has encouraged us all through.

I would extremely thanks to our internal guides Prof. Mukesh Kapoor and Prof. R. Yadav for giving us an opportunity to embark and learn this project and for his continuous encouragement throughout the preparation of this report.

I would also like to thank our external guide Shri Manohar Prasad,SM(EQ & FA), LCA TEJAS DIVISION, HAL, for his assistance and support to help us in understand and complete the internship report. I am very much tankful to him for the time and effort he has put on us.

I am thankful to the Miss Priyanka K., Mr. Senthil Kumar, Shri Ram Murthy and other teaching and non-teaching staff of our department who have helped me directly or indirectly to complete this report successfully.

THANKING YOU

INDEX1. HAL – Hindustan Aeronautics Limited

Growth & Consolidation R & D center: HAL Today Development Project: Production Units

2.Light Combat Aircraft – TEJAS

History Specifications (HAL Tejas Mk.1) Design Aerodynamics & Performance Airframe Avionics and weapon System General Systems Independent Verification And Validation Integrated Flight Control System Propulsion Systems Quality Assurance and System Effectiveness Variants First Flights Flight Testing Technology Achievements Operators

3.Bibliography1. HAL – Hindustan Aeronautics Limited

The history and growth of the Hindustan Aeronautics Limited is synonymous with the growth of Aeronautical industry in India over the past 70 years.

The Company which had its origin as the Hindustan Aircraft Company was incorporated on 23 Dec 1940 at Bangalore by Shri Walchand Hirachand a farsighted visionary in association with the Government of Mysore with an Authorized Capital of Rs.4 crores (Paid up capital Rs.40 lakhs) and with the aim of manufacturing aircraft in India. In March 1941, the Government of India became one of the shareholders in the Company holding 1/3 of its paid-up capital and subsequently took over its management in 1942. In collaboration with the Inter Continental Aircraft Company of USA, Hindustan Aircraft Company commenced its business of manufacturing of Harlow Trainer, Curtiss Hawk Fighter and Vultee Bomber Aircraft.

In Dec 1945, the company was placed under the administrative control of Min. of Industry & Supply. In January 1951, Hindustan Aircraft Private Limited was placed under the Administrative control of Ministry of Defence.The Company had built aircraft and engines of foreign design under license, such as Prentice, Vampire and Gnat aircraft. It also undertook the design and development of aircraft indigenously. In August 1951, the HT-2 Trainer aircraft, designed and produced by the company under the able leadership of Dr. V.M.Ghatge flew for the first time. Nearly 200 Trainers were manufactured and supplied to the Indian Air Force and other customers. With the gradual building up of its design capability, the company successfully designed and developed four other aircraft i.e. two seater 'Pushpak' suitable for flying clubs, 'Krishak' for Air Observatory Post(AOP) role, HF-24 Jet Fighter '(Marut)' and the HJT-16 Basic Jet Trainer '(Kiran)'.

Meanwhile, in August 1963, Aeronautics India Limited (AIL) was incorporated as a Company wholly owned by the Government of India to undertake the manufacture of the MiG-21 aircraft under license. In June 1964, the Aircraft Manufacturing Depot which was set up in 1960 as an Air Force unit to produce the Airframe for the HS-748 transport aircraft was transferred to AIL. Soon thereafter, the Government decided to amalgamate Hindustan Aircraft Limited, with AIL so as to conserve resources in the field of aviation where the technical talent in the country was limited and to enable the activities of all the aircraft manufacturing units to be planned and co-ordinated in the most efficient and economical manner.

Amalgamation of the two companies i.e. Hindustan Aircraft Limited and Aeronautics India Limited was brought about on 1st Oct 1964 by an Amalgamation order issued by the

Government of India and the Company after the amalgamation was named as "Hindustan Aeronautics Limited (HAL)" with its principal business being design, development, manufacture, repair and overhaul of aircraft, helicopter, engines and related systems like avionics, instruments and accessories.

Growth & Consolidation:

In 1970, a separate division was set up exclusively for manufacture of 'Chetak' and 'Cheetah' Helicopters in Bangalore under licence from M/s SNIAS, France. A new division was also established to manufacture aircraft instruments and accessories at Lucknow. Licence agreements were entered into with M/s Dunlop of U.K. for Wheels and Brakes, Dowty for under carriages and Hydraulic equipment, and Normal air Garret for cabin air pressurization and air-conditioning equipment, Smiths of UK, SFENA and SFIM of France for panel instruments and Gyros, Martin Baker of UK for ejection seats and Lucas for engine fuel systems, for fitment on Marut, Kiran, Ajeet, Chetak, Cheetah and Jaguar. Similar type of arrangements was agreed with USSR authorities for manufacture of accessories for MiG-21 series of aircraft.

Design and Development of Basant agricultural aircraft was undertaken between 1970 and 1974 and design and development of Ajeet, an improved version of Gnat was undertaken between 1972 and 1980. In 1976 projects were sanctioned for design & development of the HPT-32 elementary piston engine trainer, Kiran MK II (an improved version of Kiran MK I / IA) and Ajeet Trainer as well as for Advanced Light Helicopter.

In 1971, Avionics Design Bureau at Hyderabad was formed for the development and manufacture of IFF, UHF, HF, Radio components, Radio Altimeter, Ground Radars etc.,During 1973, a Design wing was set up at Lucknow for design and development of accessories such as under-carriage and hydraulic systems, air-conditioning and pressurization systems, fuel control/gauging systems, generator control and protection units, static inverters etc.,

In 1979, after seeking a licence agreement with British Aerospace, the Company started manufacture of 'Jaguar' aircraft and with Rolls Royce-Turbomeca for Adour engines. Licence agreements were also signed with different firms for manufacture of Avionics and accessories.

In 1982, the Company entered into an agreement with USSR and started production of Swing-wing MiG-27M aircraft as a follow on project for MiG-21 BIS at Nasik Division of the Company.

During 1982, Korwa Division of HAL in District Sultanpur (U.P.) was established for manufacture of Inertial Navigation System (INS), Head Up Display and Weapon Aiming Computer (HUDWAC), Combined Map and Electronics Display (COMED), Laser Ranger and Marked Target Seeker (LRMTS), Auto Stabiliser and Flight Data Recorder for Jaguar and similar advanced systems for MiG-27M.

HAL is actively engaged and is contributing to the space programmes of the country. A separate Aerospace division was established in 1988. This Division is dedicated to space programme to meet the growing requirement of Indian Space Research Organization.

In order to capture the growing market in the industrial gas turbine engines, a new Division called the Industrial & Marine Gas Turbine Division, was formed in 1998. Currently the Division is undertaking Repair and Overhaul work related with Industrial Avon Engines and Allison 501K and 571K series. In addition to this manufacture of LM 2500 engine is also being undertaken. The Division is doing the overhaul of various existing gas turbines in the country, thus providing cost-effective services to users such as ONGC, GAIL, TNEB, RSEB etc., for upkeep of their gas turbine.

An independent profit center for providing Airport related services was created in May 2000 with a view to synergize the operation of HAL Bangalore Airport. The main aim of creation of this Airport Service Centre is to restructure the existing resources to provide focused attention in relation with the exacting market needs of service segment related to airlines operations and commercially exploit the available infrastructure of the Company at Bengaluru.

With the signing of agreement with Russian partners to take up licence manufacture of SUKHOI 30 MKI Aircraft the Nasik Division which had been engaged in manufacture & overhaul of MiG series Aircraft and lately upgrade of MiGB is aircraft, had to be expanded. Accordingly it was decided in February, 2002 to have two Divisions at Nasik i.e. Aircraft Manufacturing Division for Su-30 MKI production and Aircraft Overhaul Division for overhaul and upgrade of existing MiG Series aircraft.

Consequent on decision to manufacture AL 31 FP Engine for SU 30 MK1 Aircraft, under licence from Russian Manufacturer, it was decided to establish a new Division at Koraput to take up the project in February, 2002. The project activities under the new Division have accordingly commenced. In order to facilitate Helicopter Division to dedicate itself exclusively for ALH manufacture and related activities, the manufacturing and repair / overhaul activities of Chetakand Cheetah helicopters and their variants where transferred to the Barrackpore Branch Factory and Barrackpore Division was formed and a new MRO Division created to carry out ALH Overhaul activities in 2006

Composites material is being used extensively in aircraft manufacturing for its low weight. A new Composite Manufacturing Division was formed in Mar 2007 with a dedicated manufacturing facility for composite materials for in-house projects such as ALH, LCA etc.Facilities Management Division was created in Dec 2007 for effective and focused attention towards the common services at Bangalore.

In order to boost R & D activities in-house, Mission & Combat System R & D Center was formed to concentrate on Mission systems, Aircraft upgrades and technology development in Nov

2008.Additionally, Strategic electronics Factory at Kasaragod, Kerala, a unit of HAL Hyderabad, was established Nov 2012. The in house development of Light Combat Aircraft (LCA) will give major boost to the modernization program of our Defence Services. For production of LCA, a separate Division was established at Bangalore for production of Light Combat Aircraft in Mar 2014.

R & D center:

The Company has a comprehensive Design organization in its divisions. Out of 29 types of aircraft produced so far, 15 have been of indigenous design. The Company has long experience in design and manufacture of a diversified range of aircraft and its systems. For further growth of the Company it was considered necessary for HAL to strengthen its R&D capability and accordingly the erstwhile Design Bureaus have been restructured and reorganized into the following R&D Centers: 

Sl. R & D  Centre Activity1 Aircraft R&D Centre, Bangalore Design and Development of Fixed Wing aircraft

(LCA, IJT, MTA, FGFA, UAV)2 Rotary Wing Aircraft R&D Centre,

BangaloreDesign and Development of Rotary Wing aircraft (ALH, LCH, LUH, MLH, NRUAV)

3 Mission & Combat Systems R&D Centre, Bangalore

Mission systems, Aircraft upgrades and technology development

4 Aero Engine R&D Centre, Bangalore Small, Medium Engines & Test Bed design5 Strategic Electronics R&D Centre,

HyderabadAvionics Items.

6 Transport Aircraft R&D Centre, Kanpur

Development & Modification/ upgrades of Transport Aircraft

7 Aircraft Upgrades R&D Centre, Nasik Aircraft/  System Upgrade Work on Russian Aircraft

8 Aerospace Systems & Equipment R&D Centre, Lucknow

Development of Mechanical, Hydraulic and Electrical accessories.

9 Gas Turbine R&D Centre, Koraput Design Improvement of Russian Engines10 Central Materials & Processes

Laboratory & NDT Centre, BangaloreDevelopment of Materials, Castings, Forgings & New Processes

HAL Today:

HAL is a fully owned Government of India undertaking under the administrative control of Ministry of Defence, Department of Defence Production. The Authorized Capital of HAL is Rs.600 Crore consisting of 60, 00,00,000 equity shares having face value of Rs.10 each.

The current programs under progress at HAL are production of SU-30 MKI, Hawk-AJT, Light Combat Aircraft (LCA), DO-228 Aircraft, Dhruv-ALH and Cheetal Helicopters, Repair Overhaul of Jaguar, Kiran MkI/IA/II, Mirage, HS-748, AN-32, MiG 21, Su-30MKI, DO-228 aircraft and ALH, Cheetah / Chetak helicopters.

The Company takes up maintenance and overhaul services to cover the life cycle requirement of all the old and new products. Presently, 13 types of aircraft/ helicopters and 17 types of engines are being overhauled. In addition, facilities exist for repair/ overhaul of various accessories and avionics fitted on aircraft of Russian, Western and Indigenous designs.

HAL is currently meeting the requirements of structures for aerospace launch vehicles and satellites of ISRO through its dedicated Aerospace Division. Infrastructure has also been set up to undertake completed assembly of the strap-on L-40 stage booster. Structures for GSLVMk.III have been productionised. HAL has also contributed to Mars mission by supplying riveted structural assemblies and welded propellant tankages for the Polar Satellite Launch Vehicle (PSLV-C25).

Industrial and Marine Gas Turbine: The LM-2500 marine gas turbine engine, a 20 MW aero derivative, is being produced and overhauled from the production line in the Industrial and Marine Gas Turbine Division, Bangalore. The Division also undertakes Repair and overhaul of Industrial Avon and Allison engines.

Development Project:

The major on-going indigenous development programs are the Light Combat Aircraft (LCA), Intermediate Jet Trainer (IJT), Light Combat Helicopter(LCH), and Light Utility Helicopter (LUH), Weapon System integration on ALH, Multi-role Transport Aircraft (MTA), Fifth Generation Fighter Aircraft (FGFA), and Basic Turboprop Trainer. Design and Development of medium thrust engine has also been taken up. HAL has achieved self-reliance in the area of design and

development of Helicopters and Aircraft. Technology development projects have been launched to increase self-reliance in critical areas like the Aircraft Display systems, Mission Computers, Automatic Flight Controls for helicopters, Aircraft Accessories and avionics.

Production Units:

Bangalore Complex

Aircraft Division Bangalore Engine Division Bangalore Overhaul Division Bangalore Foundry & Forge Division Bangalore Aerospace Division Bangalore Airport Services Centre Bangalore Facilities Management Division Bangalore LCA-Tejas Division Bangalore

MiG Complex Aircraft Division Nasik Aircraft Overhaul Division Nasik Engine Division Koraput Sukhoi Engine Division Koraput

Accessories Complex TAD-Kanpur Division Accessories Division Lucknow Avionics Division Hyderabad Avionics Division Korwa

Helicopter Complex Helicopter Division Bangalore Helicopter MRO Division Bangalore Barrackpore Division Composites Manufacturing Division

2.Light Combat Aircraft – TEJAS

History1.The NeedThe value of the aerospace "self-reliance" initiative was not simply the production of an aircraft, but also the building of a local industry capable of creating state-of-the-art products with commercial spin-offs for a global market. The LCA programme was intended in part to further expand and advance India's indigenous aerospace capabilities.

In the early eighties, it was realized that no organization existed which had the total capability to develop such an aircraft all on its own. The last time an indigenous fighter aircraft, the HF 24 flew was in 1961. Since then, the HF 24 assembly line had been shut down and the design team had been wound up. The only way left was to develop an aircraft from scratch.

To better accomplish these goals, the government of India in 1984 decided to establish the Aeronautical Development Agency (ADA) to manage the LCA programme. Hindustan Aeronautics Limited, (HAL) was to be the principal partner with participation of various DRDO & CSIR Laboratories, Public & private sector industries and academic institutions.

2.GenisesThe LCA design was finalised in 1990 as a small tail-less delta winged machine with relaxed static stability (RSS) to enhance maneuverability performance and a host of other advanced features. A review committee was formed in May 1989 which reported that Indian infrastructure, facilities and technology had advanced sufficiently in most areas to undertake the project. It was decided that the full-scale engineering development (FSED) stage of the programme would proceed in two stages.

Phase 1 - TECHNOLOGY DEMONSTRATION STAGE (TD-1 & 2)The focus in this phase was on ‘proof of concept’. It entailed the development and testing of two technology demonstrator aircraft. These aircraft were called TD-1 and TD-2. The decision to move forward was to be taken after the successful completion of this phase. This would be followed by the production of additional prototype vehicles. There were teething issues during this phase and finally TD-1 flew on 04 January 2001 with Wing Commander Rajiv Kothiyal on the controls. The significance of this golden-day in the history of Indian aviation can be gauged by the fact that the last time an indigenous aircraft had got airborne was almost 40 years ago on 17 June 1961.

Phase 2 - ADDITIONAL TESTING PHASE (PV-1, PV-2, PV-3 and PV-5)This phase consisted of additional testing and development of systems using Prototype Vehicles which would lead to the development of the final variant that would join the IAF and the Indian Navy. The first Prototype Vehicle, PV-1 flew on 25 November 2003.

By 2005, the Tejas had proven itself in the testing phase and the first order for 20 Series Production aircrafts was placed. A follow on order for an additional 20 SP aircraft was placed in 2010.

3.Mile Stone 1980 - 19891983 DRDO got permission to initiate a programme to design and develop a Light Combat

Aircraft.

1984 Government of India set up Aeronautical Development Agency (ADA) as the nodal agency

developing the LCA and managing the programme.

1985 IAF generated Air Staff Requirements (ASR) for LCA in October 1985.

1986 Government allocated Rs. 575 Crores for the LCA programme.

Programme to develop an indigenous power plant (engine) - Kaveri was launched at GTRE.

1987 Project definition commenced in October 1987 with French aircraft major Dassault Aviation

as consultants.

1988 Project definition phase completed in September 1988.

1989 Government review committee expressed confidence in LCA programme. It was decided

that the programme will be implemented in two phases.

1990 - 19991990 Design of LCA was completed as a tail-less compound delta winged relaxed static stability

aircraft.

Phase 1 (Technology Demonstrator) of the development was commenced to create the proof of concept.

1993 Full funding approved from April 1993 and development work for Phase 1 started in June.

1995 First technology demonstrator, TD-1, rolled out on 17th November.

1997 Multi-Mode Radar (MMR) for LCA design work started at HAL Hyderabad division and

LRDE.

2000 - 20092001 4th January - the historic first flight of the Technology Demonstrator TD-1 marking a new

era in the aviation history of India. Prime Minister Atal Bihari Vajpayee named LCA – "Tejas" meaning Radiance in ancient Indian language Sanskrit.

2002 6th June - TD-2 made her successful maiden flight.

2003 Tejas crossed the sonic barrier for the first time

25th November - PV-1 made her successful maiden flight.

2005 1st December - PV-2 made her successful maiden flight.

2006 1st December - PV-3 flew for the first time for 27 minutes at an altitude of 2.5 km and at a

speed of Mach 0.8. PV-3 was equipped with a more advanced pilot interface, refined avionics and higher control law capabilities compared with the previous versions.

2007 25th April - The first Limited Series Production LCA (LSP-1) made her first flight and

reached a speed of Mach 1.1 in the very first flight. PV-2 and PV-3 underwent sea-level trials at INS Rajali Naval Air Station, Arakkonam to

study the effects of flying at sea-level, as all earlier trials have been conducted at Bengaluru which is 3,000 feet (910 m) above sea-level. The reliability of the LCA systems under the hot and humid conditions, as well as low level flight characteristics was tested.

7th September - Tejas Prototype Vehicle (PV-1) made a successful flight with two external drop tanks of 800 Ltrs capacity

25th October - Tejas PV-1 fired R-73 (CCM) missile for the first time. The trials were conducted off the Goa coast at INS Hansa Naval Air Station.

11th December - LITENING targeting pod was successfully tested on Tejas PV-2.

2008 28th May to 4th June - LCA Tejas prototypes PV-2 & PV-3 underwent hot weather trials at

Air Force Station, Nagpur. 16th June - Tejas second Limited Series Production LCA (LSP-2) made its first flight. 7th November - LCA Prototype Vehicle-3 made first successful night flight. 13th December - PV-3 and LSP-2 completed the high altitude test at Leh, world's highest

operational airfield.

2009 22nd January - Tejas completed 1000 flights. October - PV-3 and LSP-2 completed air-to-ground weapons delivery trials. 26th November - Two seater (Trainer) version of Tejas (PV-5) made its maiden flight on 26

Nov 09. 7th December - Tejas speed envelope expanded to 1350 km/h (CAS) while performing

flight flutter test in a dive to near sea level. These tests were conducted at INS Hansa, Goa.

2010 - 20192010 6th June - TD-2 made her successful maiden flight. 23rd April - LCA Tejas LSP-3 made maiden flight. LSP-3 is close to the final configuration

including the new air-data computers. Multi-Mode Radar, new communication and navigation equipment and radar warning

receiver. With this the LCA programme has completed 1350 test flights logging about 800 flying hours.

2nd June - First Flight of LCA Tejas LSP-4. Flight. In addition to the LSP-3 standard of preparation, the aircraft also flew with the Countermeasure Dispensing System.

19 November - First Flight of LCA Tejas LSP-5.

2011 10th January - Certification for the Release to Service.

2012 9th March - The Tejas Light Combat Aircraft, LSP-7 accomplished its maiden flight from HAL

Airport in Bengaluruon 9th March 2012

29th April - The Naval version of the Indian Light Combat Aircraft Tejas, made its maiden flight from the HAL Airport in Bengaluru. This was a significant milestone in the history of Indian Aviation in designing a naval variant of a fighter aircraft.

2013 22nd February - The LCA took part in the Iron Fist Exercise in Pokhran, Jaisalmer 31st March - The Tejas Light Combat Aircraft, LSP-8 accomplished its maiden flight from

HAL Airport, Bengaluru 20th December - Initial Operation Clearance - 2

Indian Defence Minister Mr. A.K. Antony handed over the "Release to Service Document" of the country’s own Light Combat Aircraft to The Chief of Air Staff Air Chief Marshal NAK Browne.

2014 1st October - First Flight of LCA Tejas SP 1 - The first Tejas Light Combat Aircraft from the

batch of 20 ‘series production’ or full-fledged fighters flew for about 25 minutes in Bengaluru. The flight of ‘SP1’ was piloted by HAL’s Chief Test Pilot Air Cmde K.A. Muthanna(retd). The First Flight of SP1 was achieved within nine months of receiving the penultimate flight worthiness certification, called IOC-2 (initial operational clearance) in December 2013.

8th November - LCA Tejas PV-6 (Prototype Vehicle 6), a final configuration two-seater trainer aircraft, successfully completed its maiden flight at the HAL Airport in Bengaluru.

20th December - Maiden Ski Jump of LCA NP-1 - The first prototype of the light combat aircraft (LCA) Tejas Naval version - LCA NP-1 completed its maiden flight as part of the carrier compatibility tests at the shore-based test facility in Goa.

2015 17th January - IAF gets first indigenously-built Light Combat Aircraft Tejas - The LCA Tejas

Series Production-1 (SP1) was handed over by Defence Minister Mr. Manohar Parrikar to Indian Air Force Chief Air Marshal Arup Raha in Bengaluru on Saturday.

7th February - The Second Prototype of the Light Combat Aircraft, the NP-2, flew her maiden flight on 7th February 2015 from HAL Airport in Bengaluru. Piloted by Capt. Shivnath Dahiya (Indian Navy), the aircraft performed flawlessly in the first-flight

2016 21st - 23rd January - India's indigenous Light Combat Aircraft Tejas for the first time

participated in an International Air Show in Bahrain, an event witnessed by External Affairs Minister of India Smt. Sushma Swaraj.The display of India's defence technology comes at a time when the government is giving a strong push to its flagship 'Make in India' programme.

4.ADAThe nucleus of Tejas Aircraft is Aeronautical Development Agency (ADA) whose principal partner is Hindustan Aeronautics Limited. Indian Air Force, Indian Navy, DGAQA, BEL, various DRDO and CSIR Laboratories, Private and Public Sector undertakings and several academic institutions have actively participated and contributed to this truly national venture which has directly and indirectly bridged major technological gaps in several disciplines. Today we have two Technology Demonstrators (TDs), Five Prototype Vehicles (PVs) which includes Two Twin Seater / Trainer, Seven Limited Series Production Vehicles (LSP) and two Naval prototypes undergoing Flight Trials.

The LCA Tejas Series Production-1 (SP1) was handed over by Defence Minister to Indian Air Force. Initial block of flight testing of Naval variant of LCA was successfully completed. A significant milestone of the maiden ski jump launch of the first LCA Navy Prototype was successfully carried out at Goa in Dec 2014. The progress of the Tejas is well marked by completion of Initial Operational Clearance (IOC) leading to the delivery of the first Series Production (SP1) aircraft to the IAF. The programme is triumphantly moving towards certification for Final Operational Clearance (FOC).

5.NFTCNational Flight Test Centre is the directorate of ADA dealing with flight testing of LCA. All the flight test and aircraft instrumentation related activities are planned, coordinated and executed by NFTC which is headed by a Test Pilot from the Indian Air Force. NFTC has Indian Air Force and Indian Navy test pilots and flight test engineers along with the scientists and engineers for instrumentation who are professionally carrying out the flight testing of the LCA.

6.Facility New structural assembly and Final assembly facilities at HAL have been established for the

series production for IAF. Hangars have been created exclusively for the LCA program and structural assembly facilities are fully established to take up production of LCA Tejas aircraft.

Series Production aircraft are being built with assembly jigs calibrated using state of the art Computer Aided Measuring System (Laser Trackers), which is currently the international calibration practice. This will ensure consistent build quality of the aircraft with necessary Interchangeability of parts for ease of maintenance in the operating squadrons. The jigs have been calibrated to 80 microns (0.08 mm) tolerances with respect to 3D Models for inter changeability features and 0.2 mm for contours were used which would ensure high quality standard in structural build.

A state of the art wing assembly facility with a 5 axis CNC wing skin drilling machine has been commissioned to ensure excellent build quality for the Carbon Fiber Composite skin and reduced cycle time for the assembly operations of Wing. This would also ensure elimination of delamination of CFC Skins associated with manual drilling. ? Pylons and Composites Drop Tanks are manufactured in house. A drop tank test station with data acquisition and reporting system is commissioned.

Looms used in LCA are produced in LCA Tejas to stringent Quality requirements for catering EMI-EMC Specifications. Automatic Cable Testers are employed for checking and certification of looms, panels.

LCA Tejas Division has an elaborate Quality Assurance system to handle both in-house production and outsourced activities. A metrology department with coordinate measuring machines, Ultrasound Scanners complements the Quality assurance of parts.

5 Axis CNC Router CNC Precision Turn Mill Centre CNC Billet Cutting machine CNC Vertical Milling center Radial Drilling machine Lathe Cylindrical grinding machine Universal Milling machine Surface grinder

Specifications (HAL Tejas Mk.1) General characteristics

Crew: 1 Length: 13.20 m (43 ft. 4 in) Wingspan: 8.20 m (26 ft. 11 in) Height: 4.40 m (14 ft. 9 in) Wing area: 38.4 m² (413 ft²) Empty weight: 6,560 kg (14,300 lb) Loaded weight: 9,500 kg (20,944 lb) Max. takeoff weight: 13,500 kg (29,100 lb) Power plant: 1 × General Electric F404-GE-IN20 turbofan

Dry thrust: 53.9 kN (12,100 lbf) Thrust with afterburner: 89.8 kN (20,200 lbf)

Internal fuel capacity: 2,458 kg External fuel capacity: 2 x 1,200-litre drop tank inboard, 1 x 800-litre drop tank under

fuselage

Performance

Maximum speed: Mach 1.8 (2,205 km/h) for FOC version; Mach 1.6 (2,000 km/h) for IOC version;

Range: 3,000 km (1,620 nmi, 1,864 mi) Combat radius: 500 km (270 nmi, 311 mi) Ferry range: 1,700 km (1,056 mi) Service ceiling: 16,000 m (50,000 ft) Wing loading: 247 kg/m² (50.7 lb/ft²) Thrust/weight: 1.07 g-limits: +8/−3.5 g

Armament

Guns: 1× mounted 23 mm twin-barrel GSh-23 cannon with 220 rounds of ammunition Hard points: 8 (1× beneath the port-side intake trunk for targeting pods, 6× wing, and 1×

fuselage) with a capacity of 3,500 kg external fuel and ordnance and provisions to carry combinations of: Rockets: S-8 rocket pods, Bofors 135 mm rocket Missiles:

Air-to-air missiles:

Astra Derby Python-5 R-77 R-73 (missile)

Air-to-surface missiles: DRDO Anti-Radiation Missile Kh-59ME (TV-guided standoff missile) Kh-59MK (Laser-guided standoff missile)

Anti-ship missiles Kh-35 Kh-31

Bombs: KAB-1500L laser-guided bombs GBU-16 Paveway II FAB-250 ODAB-500PM fuel-air explosives ZAB-250/350 incendiary bombs BetAB-500Shp powered concrete-piercing bombs FAB-500T gravity bombs OFAB-250-270 gravity bombs OFAB-100-120 gravity bombs RBK-500 cluster bomb stake

Other: Drop tanks for ferry flight/extended range/loitering time LITENING targeting pod

Avionics

Hybrid version of Israel’s Elta EL/M-2032 multi-mode fire control radar

DesignOverview

The Tejas is a single-engine multirole fighter which features a tailless, compound delta wing and is designed with "relaxed static stability" for enhanced manoeuvrability. Originally intended to serve as an air superiority aircraft with a secondary ground-attack role, its flexibility permits a variety of guided air-to-surface and anti-shipping weapons to be integrated for multirole and multimission capabilities. The tailless, compound-delta planform is designed to be small and lightweight. This platform also minimises the control surfaces needed (no tailplanes or foreplanes, just a single vertical tailfin), permits carriage of a wider range of external stores, and confers better close-combat, high-speed, andhigh-alpha performance characteristics than comparable cruciform-wing designs. Extensive wind tunnel testing on scale models and complex dynamics analyses have optimized the aerodynamic configuration for minimum supersonic drag, a low wing-loading, and high rates of roll and pitch.

PV-3 in Indian Air Force grey camouflage pattern

Materials include aluminium-lithium, super plastically formed titanium, and carbon-fiber composites (CFC). Tejas employs CFC materials for up to 45 per cent of its airframe, including in the fuselage (doors and skins), wings (skin, spars and ribs), elevons, tailfin, rudder, air brakes and landing gear doors. The wing and fin of the compound-delta aircraft are of carbon-fiber-reinforced polymer, and were designed to provide a minimum weight structure and to serve as integral fuel tanks. Although two-seat variants are planned, the examples built to date are crewed by a single pilot on a Martin-Baker zero-zero ejection seat; a locally developed ejection seat is planned to be replace it later on. Tejas requires a very short runway and "rockets off the runway and into the air in a mere 500 meters".

All weapons are carried on one or more of seven hardpoints with total capacity of greater than 4,000 kg: three stations under each wing and one on the under-fuselage centerline. An eighth offset station beneath the port-side intake trunk can carry a variety of pods like FLIR,IRST, laser rangefinder/designator, as can the centerline under-fuselage station and inboard pairs of wing stations. Auxiliary fuel tanks of 800 and 1,200 liters can be carried under the fuselage to extend

range. An aerial refueling probe on the starboard side of the forward fuselage can further extend range and endurance. RAFAEL's Derby fire-and-forget missile will serve as the Tejas' initial medium range air-air armament.

Stealth features have been designed into Tejas. Being small provides an inherent degree of visual stealth, the airframe's high usage of composites (which do not reflect radar waves), a Y-duct inlet which shields the engine compressor face from probing radar waves, and the application of radar-absorbent material (RAM) coatings are intended to minimize its susceptibility to detection and tracking.

Aerodynamics & Performance

Tejas is an aerodynamically unstable tailless compound delta-wing configuration, optimized primarily for maneuverability and agility. Designed to meet the tactical requirements of a modern air force, Tejas is a multi-role aircraft capable of comprehensive air superiority and air defense roles. The aerodynamic design is a culmination of an intense design process involving extensive Computational Fluid Dynamics and Wind Tunnel studies. Specific aerodynamic features provide excellent aircraft performance in a wider flightenvelope:• Highly optimized wing, with appropriate variation of thickness, camber and twist along the span.• Cross-sectional area distribution along the length, adjusted for good high speed characteristics• Leading Edge slats, scheduled for favorable aerodynamic behavior• Wing-shielded bifurcated air intake duct, with diverters, suitably matched with engine to avoidbuzz and to minimize distortion throughout the flight envelope.

As a part of the aerodynamic design process, various wind tunnel models have been designed and fabricated for testing wide range of aerodynamic aspects. Computational methods have been extensively used for fuselage shape optimization, wing design, aerodynamic loads estimation in entire flight envelope, optimization of leading edge devices, performance evaluation of air intakes, configuration refinements, external stores release studies etc. The design and analysis capabilities have grown exponentially and are being refined continuously to meet future operational requirements. An impressive flight test record of more than 2850 flawless flights, amounting to nearly 2000 flying hours, is a testimony to proven design of best in class tactical fighter. Tejas flight testing is characterized by meticulous planning of test points, aerodynamic data validation and update through system identification techniques, evaluation of aircraft performance and update of performance model leading to a reliable aircraft operating data manual

AirframeMAJOR DESIGN FEATURES

• Optimized Structural Design considering strength, buckling and aero-servo-elastic

requirements for carriage of heavy external stores

• Design for manufacturing and assembly (DFMA)

• 90% of wetted surface area is made of Composites.

• Co-cured composite Fin, Co-cured and co-bonded trouser duct and engine bay door made of

high temperature composites.

• Indigenously developed metallic materials and processes like large size aluminium alloy

forgings, control stretched extrusions, merging steel and PH stainless steel

Engine Bay Door Trouser Duct

Arrestor Barrier Net Engagement (Simulation)

MLG Leg Wheel Lever

TESTING

• Ground vibration testing of stores configuration• Successful integration and flight trials of IOC stores• Integration of Health and Usage Monitoring System

Main Airframe Static Test Rig Drop Tank Emergency jettison Drop Tank Emergency Jettison Drop Tank

Avionics and weapon System

OAC MISSION & DISPLAY SYSTEM TEST FACILITY AVIONICS INTEGRATION TEST FACILITY

GLASS COCKPIT

WEAPON INTEGRATION TEST FACILITITY MULTI MODE RADAR TEST FACILITY

• Advanced Glass Cockpit with High Performance Graphics to Support Situational Awareness, Decision Support and Data Fusion• Dual Redundant Open Architecture Mission and Display Computer• UML Based Modeling, IEEE-12207, ADA-95 On-Board Flight Certified Avionics Application Software• Computer Controlled Utility System and Management System (USMS)• Helmet Mounted Sight, Multi-Mode Radar, Litening Pod and RadarWarning Receiver• Digital Weapon Management System Compatible to Russian, Western and MIL-1760C Weapons• Single Avionics Application Cater to Multiple Variants of Aircrafts• Well Proven Air-to-Air, Air-to-Ground Attack Modes

General Systems

Major Mechanical System includes Microprocessor Controlled Brake Management System, Environment Control System, Fuel System, Nose Wheel Steering System, Landing Gear System, Hydraulic System, Secondary Power System, Life Support System, and Escape System.Major LRUs Developed by ADA are Aircraft Mounted Accessories Gear Box, Filters, Up Locks, QDCs,NRV’s, Depressurization Cock, Gimble joints, Ten different types of Heat Exchangers. All LRUs have been productionised to facilitate Equipping of Series Production.

Aircraft Mounted Accessories Gear Box (AMAGB)AMAGB is a single input, multi output gear box, which receives its input drive from the engine through Power Take-Off and drives four aircraft accessories on its output pads viz., two hydraulic pumps, one generator and one starter unit. AMAGB is designed and developed by CVRDE, Chennai and production center is HAL - Engine Division, Bangalore

.

Heat ExchangersSuccessfully designed, developed by BHEL-HPVP (Formerly BHPV) and flight qualified 10 types of compact plate-fin heat exchangers for LCATEJAS aircraft.

Gimbal Assembly with Venturi

Gimbal Assy. Within venturi is designed for Max. Operating Temp: 650ºC with Max. Operating Pressure: 37bar’g’ and Movement: ±10mm (Three axes). M/s Metallic Bellows, Chennai and M/s Veekay Industries, Mumbai are the Production Centers.

Up LockTo lock the undercarriage (U/C) and its doors on retraction in the up position. Locking is mechanical and unlocking is controlled hydraulically. M/s Turbo Tech India Pvt Ltd., Bangalore is the Production Center.

Carbon-Carbon Composites for Aircraft Brakes• Provide drag• Absorb Kinetic Energy by converting into heat• Hold Aircraft stationary against Engine thrust• Carbon-Carbon Brakes are Developed by ASL, Hyderabad and Production Center Graphite India Ltd, Bangalore.

Mechanical System LRUsADA has Designed, Developed & Flight Qualified Mechanical System Line Replaceable Units (LRUs) for Hydraulic, Fuel, Environmental Control, Secondary Power Systems and other aggregates of Light Combat Aircraft (LCA). M/s GTTC, Bangalore and M/s CTTC, Bhuvaneshwar are the Production Centers. These units have been qualified for aerospace applications as per MIL standards.

Hydraulic FiltersHydraulic Filters: Hydraulic system is fitted with 9 filters of 6 types to control the particulate contamination in the system. Filter element is developed by M/s Mikro Flo Filters, Hyderbad. Production Center is M/s CTTC, Bhuvaneshwar. The high performance hydraulic filters are qualified

Independent Verification And Validation The Independent Verification & Validation (IV&V) laboratory at ADA has been set up to address the safety issues of software intensive systems of LCA Tejas, thereby obtaining a high level confidence in the operations of new systems prior to their use. IV&V plays a major role in the design and development of embedded software and ensures the development of hazard free and mission-success oriented software employing modern CASE tools viz. Modeling and simulation, Rapid prototyping, Tool based analysis and Randomized Non Real Time testing (NRT). Seven safety critical and twenty three mission critical software systems of Tejas have

been evaluated and over 2800 successful sorties of Tejas have been completed adhering to IV&V practices. The IV&V process supports standards like IEEE-12207 and RTCA DO-178B. The IV&V process has evolved to support concurrent software development techniques using OOAD and Model Driven Development (MDD) methods for LCA applications. ADA-IV&V group has also evolved the safe subset of Ada, C and VHDL languages to be used in LCA subsystems and is now in the process of evolving the guidelines for design, development, verification and certification of FPGA to be used in LCA-MK2 and future projects of ADA. Mat lab/Simulink, Rhapsody, Rational Development Suite, AdaTest, Logiscope, LDRA, and Understand for Ada/C++, Beyond Compare, Questa Prime and Clear case are some of the tools used by IV&V during various stages of development to improve the product and make it robust apart from shortening the development and certification time.

Independent Verification and Validation Test Facilities

Integrated Flight Control System• State-of-the-art Full Authority Quadruplex Digital Fly-By-wire Flight Control System• Fault Tolerant Digital Flight Control Computer with built-in Redundancy Management• Fail Operational, Fail Operational, Fail Safe DFCS and Fail Operational, Fail Safe Air Data System• Robust Control Laws for Stability and Command Augmentation, Carefree Manoeuvring, Autopilot Control and Ski Jump Functionalities• Advanced Flight Control Actuators incorporating both Hydraulic and Electrical Redundancy

• Range of Ground Based Test Facilities for Integrated Flight Control System Development, Handling Qualities Evaluation, Non-Real Time Tests, Real Time Simulation, Hardware-in-loop Simulation, Structural Coupling Tests, Lightning Test, Ground Check out Systems and Flight Test• Test Facilities equipped with State-of-the-art Flight Dynamic Simulator, Engineering Test Station, Air Data Test Station, High End Projection Systems, Data Acquisition, Analysis and

IRON BIRD LIGHTNING TEST FACILITY

REAL TIME SIMULATOR ENGINEERING IN LOOP SIMULATION

MINI BIRD FACILITY SYSTEM ANALYSIS & EVALUATION FACILITY

Propulsion Systems Propulsion System consists of Engine – GE-F404-IN20 for LCA Mk1, GE-F414-INS6 for LCA Mk2 Jet Fuel Starter (JFS) Engine Health Monitoring Electronic Unit Engine Parts Life Tracking and Management System (Net enabled Ground Stations) Engine maintenance shop and Engine Test Facilities Completion of Propulsion Systems flight test points for Full Operational Clearance (FOC) Demonstration of high angle of attack capability, and altitude up to 15 km. Demonstration of in-flight relight capability Demonstration of operation from high altitude, cold weather conditions at Leh, Ladakh. Impeccable maintenance record of Engine and Jet Fuel Starter Engine Integration activities of GE-F414-INS6 in LCA Mk2 on schedule Portable Engine Maintenance Test Facility under development

Quality Assurance and System Effectiveness

Quality Assurance and System Effectiveness plays a vital role in product assurance ensuring Airworthiness and safety of aircraft• Reliability and Maintainability• Survivability• System Safety and Air Worthiness• Quality Engineering

Reliability &Maintainability Product Assurance

Quality Engineering

Survivability System Safety & Air Worthiness

VariantsPrototypesAircraft already built and projected models to be built. Model designations, tail numbers and dates of first flight are shown.

Technology Demonstrators (TD)

TD-1 (KH2001) – 4 Jan 2001 TD-2 (KH2002) – 6 June 2002

Prototype Vehicles (PV)

PV-1 (KH2003) – 25 November 2003 PV-2 (KH2004) – 1 December 2005 PV-3 (KH2005) – 1 December 2006. This is the production variant. PV-4 PV-5 (KH-T2009) – 26 November 2009 – Fighter/Trainer Variant PV-6 (KH-T2010) - 8 November 2014 - Fighter/Trainer Variant.

Naval Prototypes (NP)

NP-1 (KH-T3001) – Two-seat Naval variant for carrier operations. Rolled out in July 2010. NP-1 made its first flight on 27 April 2012.

NP-2 (KH3002) – First flight on 7 February 2015 with sky-jump take-off and arrested landing required in STOBAR carrier.

NP-3 & NP-4 – Single-seat LCA MK 2 Naval variant for carrier operations to be powered by the GE-414 engines. The design work on the two aircraft is nearly complete.

NP-5 – Another Single-seat LCA MK 1 Naval variant is planned so as to enhance the pace of certification process for Naval LCA.

Limited Series Production (LSP) aircraft

Currently, 8 LSP series aircraft plus 40 aircraft are on order.

LSP-1 (KH2011) – 25 April 2007. This LCA is powered by F404-F2J3 Engine. LSP-2 (KH2012) – 16 June 2008. This is the first LCA fitted with F404-IN20 engine. LSP-3 23 April 2010. The first aircraft to have the Hybrid MMR radar[48] and will be close to

the IOC standard. LSP-4 (KH2014) – 2 June 2010. The first aircraft that was flown in the configuration that will

be delivered to the Indian Air Force. In addition to the Hybrid MMR, the aircraft flew with a Countermeasure Dispensing System and an identify friend or foe electronic system.

LSP-5 (KH2015) – 19 November 2010. IOC standard, with all sensors including night lighting in the cockpit, and an auto-pilot.

LSP-6 – Will be used to increase the Angle of Attack. As well as develop better (Experimental) RAM coating to further reduce its radar signature.

LSP-7 (KH2017) – 9 March 2012. APU intake has been aerodynamically reshaped. LSP-8 – First flight trial completed in March 2013. LSP 8 is the version that will go for

production.

SP-1 to SP-20 – It was planned to fly by late 2013. The SP-1 and SP-2 will be part of No. 45 Squadron (Flying Daggers) that will be based initially in Bangalore (Bengaluru), Karnataka. In May 2014, HAL planned to deliver four SP aircraft to the IAF. SP-1 took its maiden flight on 30 September 2014. On 17 January 2015 first SP-1 was handed over to Indian Air Force by Defence Minister Sh. Manohar Parrikar. SP2 took its maiden flight on 22 March 2016

Planned production variants

Tejas Trainer - Two-seat operational conversion trainer for the Indian Air Force. Tejas Mark 1A HAL is now working on developing a new variant named Tejas Mark IA which

will be equipped with an advanced AESA Radar and an electro-optic Electronic Warfare (EW) sensor suite. It will also incorporate weight reduction along with easier service maintainability which will thus reduce downtime of each aircraft. It will also have a mid-air refueling probe to enhance its endurance and operational range. The timeline for this variant has been set at 2017. On 25 October 2015, it was reported that 100 Tejas aircraft will be equipped with an improved version of the EL/M-2052 AESA radar being developed jointly by Elta and HAL.

Tejas Trainer IN - Two-seat operational conversion trainer for the Indian Navy. Tejas MK1 Navy - Single seat prototypes (NP1 & NP2) powered by F404 engines are used

for the initial testing. The Naval variant of Tejas successfully completed testing in Goa during which the short take off (200 meter) from Shore Based Test Facility were carried out along with hot refueling. The flight test from aircraft carrier is scheduled for 2017.

Tejas Mk2 Navy -Twin- and single-seat carrier-capable variants for the Indian Navy. It will be equipped for carrier operation with ski-jump take-off and arrested landing. It will include strengthened airframe and landing gear and drooped nose for better cockpit vision. The Tejas Mk 2 Navy will have a length of 14.2 meters (1 meter more than that of the Tejas Mk 1, for incorporating a stretched nose section and a modified fuselage section aft of the cockpit for housing an expanded complement of mission avionics LRUs), height of 4.6 meters (as opposed to 4.4 meters of the Tejas Mk 1, to accommodate an enlarged vertical tail-section) and a wingspan of 8.2 meter, same as that of the Tejas Mk 1, however with an increased wing area. External stores capacity will be boosted to 5,000 kg (as opposed to 4,000 kg for the Tejas Mk 1), while the twin internal air-intake ducts will be minimally enlarged to cater to the increased airflow requirements of the 98 kN thrust F414-GE-INS6. The Ministry of Defence had sanctioned US$542.44 million (Rs 2,431.55-crore) for ADA to develop the Indian Navy's LCA Mk 2 (Navy) variant. The IAF is committed to procuring an initial 83 Tejas Mk 2s and the Indian Navy has expressed a firm requirement for 46 LCA Mk2 (Navy). The Mark 2 may feature an indigenously developed active electronically scanned array (AESA) fire control radar named Uttam. The Mk2 will also see the incorporation of a new electronic warfare suite which is being jointly developed with Israel. This is to have a new glass cockpit with larger 8 x 12 inch displays. The Mk2 will have some 25-30 percent commonality in parts with the Mk1 and these parts are already in

production. The Mark 2 is scheduled for flight testing by 2018, but this may be delayed by two or three more years to allow time to engineer the installation of the GE 414 engine. In August 2015, the Indian defence minister stated the first flight is likely to be 2019 with an entry into service in 2022.

Tejas Mark 2 - The Tejas Mark 2 is to feature the more powerful General Electric F414-GE-INS6 engine with 98 kN of thrust and refined aerodynamics. The Mark 2 is being developed to meet the latest IAF requirements and will incorporate fifth-generation jet fighter elements which are intended to make way into the FGFA and AMCA. The Tejas Mk 2 will have a length of 14.2 meter (1 meter more than that of the Tejas Mk 1, for incorporating a stretched nose section and a modified fuselage section aft of the cockpit for housing an expanded complement of mission avionics LRUs), height of 4.6 meter (as opposed to 4.4 meters of the Tejas Mk 1, to accommodate an enlarged vertical tail-section) and a wingspan of 8.2 meters, same as that of the Tejas Mk 1, however with an increased wing area. External stores capacity will be boosted to 5,000 kg (as opposed to 4,000 kg for the Tejas Mk 1), while the twin internal air-intake ducts will be minimally enlarged to cater to the increased airflow requirements of the 98 kN thrust F414-GE-INS6. The Ministry of Defence had sanctioned US$542.44 million (Rs 2,431.55-crore) for ADA to develop the IAF's Tejas Mk 2 variant. The IAF is committed to procuring an initial 83 Tejas Mk 2s. The Mark 2 may feature an indigenous developed active electronically scanned array (AESA) fire control radar named Uttam. The Mk2 will also see the incorporation of a new electronic warfare suite which is being jointly developed with Israel. This is to have a new glass cockpit with larger 8 x 12 inch displays. The Mk2 will have some 25-30 percent commonality in parts with the Mk1 and these parts are already in production. The Mark 2 is scheduled for flight testing by 2018, but this may be delayed by two or three more years to allow time to engineer the installation of the GE 414 engine.

In August 2015, the Indian defense minister stated the first flight is likely to be 2019 with an entry into service in 2022. In October 2015, media reports suggested the government has decided to order the modified Tejas Mk 1A instead of the Tejas Mk 2.

LCA AF MK1 FIGHTER

PERFORMANCE Max speed : Supersonic at all altitudes Service Ceiling : 50,000 ft ‘g’ Limits : +8/-3.5

DIMENSIONS Span : 08.20 m Length : 13.20 m Height : 04.40 m

WEIGHT Take-off Clean : 9800 kg Empty : 6560 kg

External Stores : 3500 kg

POWER PLANT F404-GE-IN20

SPECIAL Features Compound Delta Planform Relaxed Static Stability Relaxed Static Stability Composite Structure Fly-by-wire Flight Control Computer based monitor and control of Electro Mechanical Systems Glass Cockpit Multi-Mode Radar

LCA AF MK1 Trainer

An operational type trainer & two seat aircraft for Tejas AF Mk1; has been developed by ADA and its partners

Two prototype trainer aircraft (PV5 and PV6 the Aircraft being close to series production trainer); are currently undergoing rigorous flight tests

Tejas AF Mk1 Trainer Final Operational Clearance (FOC) target is December 2015 Tejas Trainer will have capabilities close to the fighter

¤ Air-to-air Missiles ¤ Conventional Bombs ¤ Conventional Bombs

Four plus generation technologies including:• Open Architecture Avionics with Glass Cockpit• Quadruple Digital Flight Control System• Extensive use of Carbon Composites in Aircraft Structure

Flight Envelope• Speed: 1.6 Mach• Structural Load Limits: +8g and -3.5g• AOA: 26˚• Ceiling: 50,000 ft

All Weather and Day / Night Operations Eight hard stations to carry sensors, external fuel tanks for extended range and various

weapons including BVR missiles and Laser guided bombs Tejas Trainer will facilitate smooth graduation of young IAF pilots to Tejas AF Mk1 Fighter It can also play the role of a Generic Military Fighter Trainer

LCA AF Mk2LCA AF Mk2 is an improvement over LCA AF Mk1 with higher thrust engine. This aircraft will have improved survivability, maintainability and obsolescence mitigation. Active Electronically Scanned Array (AESA) Radar, Unified Electronic warfare Suite (UEWS) and On-Board Oxygen Generation System (OBOGS) are some of the state of the art technologies planned to be integrated. The cockpit design has been improved with bigger size, smart Multi-function Displays (MFD) and smart Head up Display (HUD).

KEY FEATURES• Improved Performance, Survivability & Maintainability• Higher thrust Engine• Aerodynamic improvements• Active Electronically Scanned Array (AESA) Radar• Digital Flight Control Computer Upgrade• Unified Electronic Warfare Suite• Avionics Upgrade• Glass Cockpit• Fuel Dumping System• On Board Oxygen Generation System• Increased Fuel Capacity• Increased Pay load• Obsolescence Management

DIMENSION Span: 8.2 m Length: 13.7 m Height: 4.4 m

POWERPLANT GE-F414-INS6

PERFORMANCE Service Ceiling: 15 km ‘g’ Limits : +9 / -3.5 Max speed: Supersonic

Improved Cock (OBOGS) (AESA) Radar

On-Board Oxygen Generation System (OBOGS)

Active Electronically Scanned Array (AESA) Radar

LCA Navy Mk1

LCA Navy Programmed to design and develop a Carrier Borne Fighter Aircraft was sanctioned in 2003 after the successful initial flight testing of LCA (Air Force) variant, Teas. Two prototypes, a two seat Trainer (NP1) and a single seat Fighter (NP2) with more internal fuel have been developed in Phase-1 of the programme. These two aircraft will be used as Technology Demonstrators to carry out Carrier Suitability Certification and Air Defence Weapon Integration. After initial testing in a typical Air Force ‘up & away’ flight envelope, Carrier Compatibility Test (CCT) will be carried out in the Shore Based Test Facility (SBTF) built at the Naval Air Station at Goa, replicating an aircraft carrier having Restraining gear and Ski-jump for take-off.

The first LCA Navy prototype, NP1 had its maiden flight on 27 Apr 2012. Since then, it has undergone 3 blocks of flight testing, where it has successfully completed various manoeuvers, flown with centerline drop-tank integrated and has also flown at supersonic speed.

NP1 aircraft has successfully made its maiden Ski-jump Take-off from the Shore Based Test Facility (SBTF) at Goa on 20 Dec 2014. The aircraft is currently undergoing next phase of flight testing.The second prototype and the first naval fighter version NP2 has successfully completed its maiden flight in Feb 2015.Once proved ashore, aircraft is cleared for flights on the Carrier for its carrier compatibilityTake-off AreaLanding area

Optical Landing System

Optical Landing System

Landing area

Take-off Area

LCA Navy Mk2

Phase-2 of LCA Navy Programme envisages development of two single seat Fighter aircraft with a new higher thrust engine (GE-F414-INS6) and further design optimization to reduce drag. LCA Navy Mk2 would undergo weight reduction through a redesigned landing gear and associated structure and increased internal fuel as critical driving factors in its design. LCA Navy Mk2 will have enhanced mission performance and better maintainability.

KEY FEATURES• Single Seat Fighter aircraft with optimized fuselage and wing aerodynamics• Higher thrust from new engine: GE-F414-INS6• Redesigned lighter Landing Gear and Arrestor Hook System• Improved mission performance• Fuel Dump System• Designed for up to 4.5g deceleration during arrestment

ROLE• Air to Air• Air to Sea• Air to Ground

DIMENSIONSpan: 8.9 mLength: 14.56 mHeight: 4.64 m

First Flights

The Tejas is a pilot’s aero plane and nowhere is this more evident than in her handling qualities and performance characteristics. She rockets off the runway and into the air in a mere 500 meters, and her control harmony and carefree handling characteristics are clearly demonstrated in the almost poetic ballet in the air that is the aerobatic display routine. Frugal fuel consumption and inbuilt air refuelling capability leave the Tejas with combat legs that will be the envy of many a contemporary platform. A fighter pilot with minimal experience will be able to handle the Tejas in the air with ease, and her small size and exceptional manoeuvrability makes the Tejas an opponent that not many will choose to tangle with.

Aircraft Aircraft No. First Flight Pilot

TD-1 KH2001 04-Jan-2001 Wg. Cdr. Rajiv Kothiyal

TD- 2 KH2002 06-Jun-2002 Wg. Cdr. Tarun Banerjee

PV-1 KH2003 25-Nov-2003 Sqn. Ldr. Suneet Krishna

PV-2 KH2004 01-Dec-2005 Wg. Cdr. Vikram Singh

PV-3 KH2005 01-Dec-2006 Gp. Capt. Harish

LSP-1 KH2011 25-Apr-2007 Gp. Capt. AP Singh

LSP-2 KH2012 16-Jun-2008 Wg. Cdr. N Tiwari

PV-5 KH-T2009 26-Nov-2009 Gp. Capt. R Tyagi & Air. Cmde. Rohit Varma

LSP-3 KH2013 23-Apr-2010 Wg. Cdr. G Thomas

LSP-4 KH2014 02-Jun-2010 Gp. Capt. Suneet Krishna

Aircraft Aircraft No. First Flight Pilot

LSP-5 KH2015 19-Nov-2010 Lt. Cdr. Ankur Jain

LSP-7 KH2017 09-Mar-2012 Gp. Capt. KK Venugopal

NP-1 KHN-T-3001 27-Apr-2012 Commodore J.A. Maolankar & Wg. Cdr. M Prabhu

LSP-8 KH2018 31-Mar-2013 Air Cmde K A Muthanna(retd)

SP-1 LA-5001 01-Oct-2014 Air Cmde K.A. Muthanna(retd)

PV-6 KH-T-2010 08-Nov-2014 Gp. Capt Vivart Singh & Gp Capt Kabadwal

NP-2 NAVY-3002 07-Feb-2015 Capt. Shivnath Dahiya

FLIGHT TESTING

National Flight Test Center is the directorate of ADA dealing with flight testing of LCA. All the flight test and aircraft instrumentation related activities are planned, coordinated and executed by NFTC which is headed by a Test Pilot from Indian Air Force. NFTC has Indian Air Force and Indian Navy test pilots and flight test engineers along with the scientists and engineers for instrumentation who are professionally carrying out the flight testing of the LCA

National Flight Test Centre R73 E Missile Firing

Flight Test at Leh Rear View from LCA Cockpit

TECHNLOGY

Tejas Composites

The Tejas employs CFC materials for up to 45% of its airframe, including in the fuselage (doors and skins), wings (skin, spars and ribs), elevons, tailfin, rudder, air brakes and landing gear doors. Composites are used to make an aircraft both lighter and stronger at the same time compared to an all-metal design, and the LCA's percentage employment of CFCs is one of the highest among contemporary aircraft of its class. Apart from making the plane much lighter, there are also fewer joints or rivets, which increases the aircraft's reliability and lowers its susceptibility to structural fatigue cracks.

The use of composites in the LCA resulted in a 40% reduction in the total number of parts compared to using a metallic frame. Furthermore, the number of fasteners has been reduced by half in the composite structure from the 10,000 that would have been required in a metallic frame design. The composite design also helped to avoid about 2,000 holes being drilled into the airframe. Overall, the aircraft's weight is lowered by 21%. While each of these factors can reduce production costs, an additional benefit — and significant cost savings - is realised in the shorter time required to assemble the aircraft — seven months for the LCA as opposed to 11 months using an all-metal airframe.

Glass cockpit

The term Glass Cockpit refers to a modern cockpit in which all the round dialled electro-mechanical instruments have been replaced with Multi-Function Displays (MFDs) and a Head Up Display (HUD). A glass cockpit uses several displays driven by flight management systems, which can be adjusted to display flight information as needed. This simplifies aircraft operation and navigation and allows pilots to focus only on the most pertinent information. The MFDs are colour Active Matrix Liquid Crystal Displays (AMLCDs) Information required by the pilot to take-off, navigate, perform his operational mission, deliver his weapons, cope with enemy threats, return to base and land is gathered by sensors on board the aircraft, processed by a mission computer and then displayed on the MFDs and HUD.

Fly by wire

Tejas is equipped with a quadruplex digital fly-by-wire flight control system to ease handling by the pilot. The digital FBW system of the Tejas employs a powerful digital flight control computer (DFCC) comprising four computing channels, each with its own independent power supply and

all housed in a single LRU. The DFCC receives signals from a variety of sensors and pilot control stick inputs, and processes these through the appropriate channels to excite and control the elevons, rudder and leading edge slat hydraulic actuators. The DFCC channels are built around 32-bit microprocessors and use a subset of the Ada programming language for software implementation. The computer interfaces with pilot display elements like the MFDs through MIL-STD-1553B multiplex avionics data buses and RS-422 serial links.

Tejas is intentionally made longitudinally unstable to enhance manoeuvrability. The Control laws (CLAW) recover Stability and provide good Handling Qualities to the Pilot. They also provide invariant response with respect to variation in aerodynamics, fuel etc. and facilitate robust performance. The CLAW is carefree and ensures that various aircraft parameters are limited automatically. This enables the pilot to fly the mission without worrying about exceedance of parameters beyond a safe limit.

The autopilot provides pilot relief functions. This helps the pilot to do more head down activities (especially mission critical activities) without being concerned about the aircraft departing from its flight path. The autopilot is also equipped with advanced features like auto level (which helps the pilot recover the aircraft if he gets disoriented and also during night flying), safe altitude recovery (which automatically pulls up the aircraft if it comes too close to the ground) and navigation modes (which steer the aircraft automatically along a pre-determined flight path).

Compompound delta wings

The Tejas is a tailless, compound delta planform. This planform is designed to keep the Tejas small and lightweight. The use of this planform also minimises the control surfaces needed (no tailplanes or fore planes, just a single vertical tailfin), permits carriage of a wider range of external stores, and confers better close-combat, high-speed, and high-alpha performance characteristics than conventional wing designs. Extensive wind tunnel testing on scale models and complex computational fluid dynamics analyses have optimised the aerodynamic configuration of the LCA, giving it minimum supersonic drag, a low wing-loading, and high rates of roll and pitch.

Multimode readar

The coherent pulse-Doppler Multi Mode Radar is designed to operate equally effectively in the Air to Air and Air to Surface domains. Jointly developed as an Indian – Israeli venture, it features multi-target Air to Air Track, Hi Resolution Synthetic Aperture Mapping and specialized Air to Sea modes. The radar facilitates all weather employment of a variety of Air to Air and Air to Surface Weaponry, and is the primary targeting sensor on the Tejas.

Open Architecture Computer (OAC)

Designed and developed by ADA, combines the functions of earlier mission computer, display processor, video switching unit, and mission preparation and retrieval unit. It is designed based on open system interfaces standards, which provides interoperability, scalability, and portability. OAC drives three multi-function displays, HUD and the helmet-mounted display. This open architecture design will allow the designers to continuously adapt and upgrade Tejas to meet the challenges of modern warfare.

ACHIEVEMENTS

The first prototype of the light combat aircraft (LCA) Tejas’ Naval version - LCA NP1 completed its maiden flight as the part of the carrier compatibility tests at the shore-based test facility in Goa. Tejas has participated in Hot Weather, Cold Weather, Iron Fist, Weapon Trials comprising of Bomb releases in CCRP/CCIP, R73E missile launching in MMR/HMDS Guided Mode, Stick bombing and separation trials of emergency Jettison of multiple stores/ Drop tank conducted at various locations in India.

• Air superiority missions with R73E CCM guided by MMR/ HMDS successfully demonstrated.• Operational Air Support Missions with 1200/800 Ltr Drop tank & 1000 lb bombs in CCRP/CCIP modes completed.• Laser guided missions with Litening POD demonstratedfor IOC envelope.• Multi role capability demonstration during IRON FIST by simultaneous release of Laser guided bomb, Chaff & Flare dispensation and R73E missile within a span of 100 secs.• Night Flying.• Wake Penetration.

• Successfully completed more than 2871 flights. Sensor evaluation of MMR, Litening POD, HMDS, RWR, TACAN, IFF, VOR-ILS successfully completed.

• Spool down engine relight successfully demonstrated.• Envelope expansion upto 24˚ AOA completed.• Chaff & Flare dispensation integrated with RWR successfully completed.• Operational Readiness Platform scramble readiness demonstrated.• Fuel System, Brake Management System and General Systems performance demonstrated.• Production Equipment Standard of Preparation & Drawing Applicability Lists(SOP/DAL) released.• The First LCA Navy Prototype has completed its maiden Ski-Jump launch at Goa in Dec 2014

LCA Under Wet Runway Trials LCA Under Night Flying Trial

Release of Bomb from LCA

LD Pod Integration on LCA LCA Under Hot weather Trial (Temperature >48° C)

Operators India

Indian Air Force – 100 LCA [20 x Mk 1 + 80 x Mk 1A] aircraft planned to be acquired plus 8 Limited Series Production (LSP) aircraft. Four squadrons of LCA Mk 2 aircraft planned to be acquired after completing production of LCA Mk 1. The IAF was considering at least 14 Tejas squadrons with 294 aircraft in February 2014, with each squadron to have 21 aircraft.

Indian Navy – Signed an order for six Naval LCAs at an approximate cost of US$31.09 million per aircraft. The Indian Navy has a requirement for 40 Tejas aircraft.

3.Bibliography

www.tejas.gov.in www.wikipedia.org www.airforce-technology.com www.defenseindustrydaily.co

m www.newsonair.com ADA Tejas Brochure 2015