HAL Is not willing to Swap Engines for Tejas Mk1A Amid F404 Supply Delays,Eyes Stabilization by 2026

Описание: Amid ongoing delays in the supply of General
Electric's (GE) F404 engines for the Tejas Mk1A
program, a senior official from Hindustan
Aeronautics Limited (HAL), speaking to idrw.org on
condition of anonymity, has clarified that the
company has no plans--nor is it considering--
replacing the current F404 engine with alternative
options.


Despite the supply chain bottlenecks, HAL and the
Indian Air Force (IAF) remain aligned in their
commitment to the F404, with expectations that
GE's deliveries will stabilize and pick up pace from
2026 onwards. The decision underscores the
technical and logistical complexities involved in
switching engines, which could further delay the
induction of the Tejas Mk1 A into IAF service


When asked by idrw.org why HAL is not exploring
other engine options, even as an experimental
measure on older Tejas airframes, the HAL official
outlined the myriad technical challenges such a
switch would entail. The Tejas Mk1A has been
meticulously designed, optimized, and tested
around the F404-IN20 engine, and replacing it with
another powerplant--such as the Eurojet EJ200,
Safran M88, or even an indigenous option like the
Kaveri (if revived)--would require significant
redesign and re-certification efforts.


The official detailed the following complexitiesStructural Adjustments to Airframe and Engine
Bay: A new engine would necessitate


modifications to the Tejas Mk1 A's engine bay,
including changes to the mounting system,
cooling ducts, and exhaust system. Different
engines have unique dimensions, weight
distributions, and thermal profiles, all of which
would require structural adjustments to
accommodate them without compromising the
aircraft's integrity


2. Recalibration of Weight Distribution: Switching
engines would alter the aircraft's center of gravity,
requiring recalibration to ensure aerodynamic
stability and handling. This process involves
extensive computational analysis and flight
testing to validate performance across the
aircraft's operational envelope.


3. Extensive Re-Engineering and Testing: Beyond
physical modifications, a new engine would
demand updates to the aircraft's digital flight
control system (DFCS), fuel system, and avionics
interfaces. The Tejas Mk1A's fly-by-wire system
optimized for the F404's thrust profile, would need
reprogramming to adapt to a different engine's
performance characteristics. This would trigger a
lengthy cycle of ground and flight testing, followed
by re-certification by agencies like the Centre for
Military Airworthiness and Certification
(CEMILAC).Supply Chain and Logistics Implications:
Introducing a new engine would also disrupt HAL's
existing supply chain, requiring new vendor
agreements, spare parts inventories, and
maintenance protocols. This could further
complicate logistics for the IAF, which already
operates a diverse fleet of aircraft with varying
engine types.


The HAL official emphasized that these challenges
outweigh the potential benefits of switching
engines, especially since the delays in F404 supply
are viewed as a temporary setback rather than a
long-term crisis. "The Tejas Mk1A has already been
optimized and tested with the GE F404-IN20.
Switching engines would require extensive flight
testing and re-certification, which could push
timelines back by years, the official noted.


Despite the delays, HAL and the IAF appear to be on
the same page regarding the path forward. Both
entities are banking on GE's assurances that the
F404 supply chain will stabilize by 2026, enabling a
steady flow of engines to support HAL's production
ramp-up. The IAF, which has long championed the
Tejas program as a cornerstone of its modernization
efforts, seems willing to wait out the supply
disruptions rather than risk further delays by
embarking on an engine replacement endeavor.


The HAL official expressed confidence in GE's abilityto resolve its supply chain issues, pointing to
ongoing discussions between HAL, GE, and the US
government to expedite deliveries. "GE has
committed to picking up the pace in 2026 onwards,
and we expect deliveries to stabilize thereafter," the
official told idrw.org. This timeline aligns with HAL's
production targets, which aim to deliver 16-18
Mk1A aircraft annually once the supply chain
bottlenecks are resolved


When pressed on whether HAL could experiment
with alternative engines on older Tejas Mk1
airframes as a proof-of-concept, the official
reiterated the impracticality of such an approach
Older Tejas airframes, primarily used for training or
testing, are also built around the F404 engine, and
retrofitting them with a new powerplant would
involve the same structural and systems-level
modifications required for the Mk1A. Moreover, such
experiments would divert resources-both financial
and human--from HAL's primary goal of scaling up
Mk1A production and progressing the Tejas Mkll
and AMCA programs.
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