KDE parts manufactured by Godrej aerospace:
Thank you for the link. From GTRE it is clear as I understand, that they are not working on Kaveri for Tejas .
This is fine, so it confirms that we are not going for any further development of the Kaveri 90KN version but for the 110KN thrust, which is going to be used in the MK2 and AMCA. Maybe once we master the 110 KN, we will do a downgraded derivative version of 90 KN of LCA export in the future as a low-cost fighter.
The discussion was more regarding Navy than of drones. Very little was discussed on drones. However it is illuminating.
Domestic hydraulic press makers are also starting to catch up:
I have a rant regarding this "development" that Kaveri isn't going to be fitted on Tejas! The esteemed forum members may be kind enough to indulge me for that.Ok, i didn't watch that far. He should have been clear in the presentation by saying KDE and UAV.
This view IF true, is a disaster of a decision since it leaves us totally at the mercy of a hegemon whose only objective is world dominance by hook or crook. Most of our fighter aircrafts will be left at the mercy of a foreign power's whims and fancies. This won't be equivalent to flying the TDs when sanctions were imposed by the hegemon but still we kept the program going maybe based upon the spares we brought earlier in anticipation of sanctions or some other jugaad at that time. Frontline deployed fighter jets need full support of OEM's for spares especially for the jet engine and that's exactly the pressure point which this hegemon will totally utilize to arm-twist us.
Kaveri++ or whatever u want to call, would have allowed us to free ourselves from such slavery. I used all caps "if" earlier because the GTRE guy may have been instructed from higher ups to not disclose anything regarding our Kaveri++ efforts because maybe we don't want the foreign powers to know about it or maybe for some other valid reason. This behaviour has earlier precedence as well so I am not exactly shooting arrows in the dark. Plus we have all read about some supposed new AB from Brahmos Corp and the recent tender of SX blades by GTRE which was most probably for Kaveri so there are hints out there that we are doing something about Kaveri++ but yes no outright confirmation about it other than this video where it's cancelled as per the GTRE gentleman. One more thing that the GTRE guy said that caught my ears is that our existing engine test beds are occupied 365 days! So again, what are we testing so much if not something like Kaveri++? Ofcourse all those testing will not be for Kaveri++ but other than Kaveri engine project we don't have any other major jet engine program going on (atleast as per public knowledge). So for what we have our testbeds occupied for 365 days?
Kaveri++ will give us not only a replacement for F404 but if we hit 90 kN then we are at F414 level since Kaveri is designed for Indian operating conditions and hence doesn't undergo loss of thrust unlike the burger series. As per some news articles the Tejas will undergo three engine changes through their entire life so we can replace the burger series with our own engines even if it may be too costly to do. No cost considerations must hinder the process of indigenization and strategic freedom, that's what I believe in. It will only end up helping us to industrialize more and that too in a core and very complex engineering process! So personally I REALLY REALLY want GoI/DRDO/GTRE/IAF to develop Kaveri++.
I would also like to add that as per my understanding (not an aeroengine guy!) a derated 110KN won't be possible since the design of a 90kN and a 110-120kN engine will be very different so both these engine efforts have to be separate from each other. Kaveri++ is our only way forward for a 90kN engine in the shortest period of time.
During the discussion on Navy turbine engines and drones, one retired engineer from GTRE suggested that we should adopt Chinese method of testing of the engine for flying test. During his visit to Russia Air show, he enquired from Chinese how they are able to test the engines and certify so fast. They told that Chinese do incremental testing, first for 5 minutes on the flight (test) then increase to 10 minutes. It was also discussed that Indians try to incorporate all the best specifications that are available in the world and hence will never be able to achieve anything in time or get delayed in achieving the targets.
Right now, we don't have a working 90 KN Kaveri engine. we are working on the certification of the dry thrust variant. This may take another two or three years, and in parallel, BrahMos Aerospace will work on the afterburner section, but there is no guarantee that we will be able to get the desired result. So the next upcoming requirement is the Mk2 and AMCA, and we need a 110 KN engine. GTRE is not confident or doesn't want to take the risk to do this alone in the given timeframe. So they are asking for a partner who will guide them to build and create all the test facilities that they will use for the future development. Now if we will have a 90 KN engine similar to GE 404, we will use it in LCA; else a working engine will always be in our inventory for future use, similar to PTAE 7. Now I am not sure what the MOD budget plan is for this; there is nothing as of now signed on paper... similar discussions happened earlier also. Governments need to see the aviation sector as a job creation sector.
3D printed components of various engines made by Indian industry (HAL, Wipro 3D, GTRE etc.):
Kaveri engine parts:
Dynamic seals of Kaveri:
Wipro 3D printed part for Turbomeca Artouste used on Cheetah/Chetak:
Su-30 engine fuel elbow:
HAL HTFE blades, vanes & fuel holder:
Kaveri engine parts:
Dynamic seals of Kaveri:
Wipro 3D printed part for Turbomeca Artouste used on Cheetah/Chetak:
Su-30 engine fuel elbow:
HAL HTFE blades, vanes & fuel holder:
Fan Inlet casing of GTRE Kaveri by Godrej:
Great thread on TBC. I have added some photos:
Thread:
Thermal barrier coating Thermal barrier coating is the one key technology for our upcoming fighter jet engine. Thermal barrier coating (TBC) is a protective layer applied to metallic components to shield them from extreme heat and harsh conditions.
The two primary methods for applying thermal barrier coatings (TBCs):
1. Plasma spray.
2. Physical Vapor Deposition (PVD)
Plasma spray: Plasma spray is a thermal spraying process that uses a high-temperature plasma jet to melt and coat a surface with various materials.
Physical vapor deposition (PVD): PVD is a technique that uses physical processes to create thin films on surfaces. It's also known as thin-film coating. DMRL and ARCI. Both are together working on thermal barrier coating.
EB-PVD unit developed by DMRL and ARCI:
Advantages of EB-PVD:
1. Coatings obtained are dense, uniform and smooth
2. Deposition rates a high as 50-100 pm/min.
3. productivity of 10-15 kg/hr possible.
4. Large window of coating thickness (10pm-2 mm).
5. Ability to coat thin foils, strips, sheets & heavy blanks.
APPLICATIONS OF EB-PVD COATINGS: By changing the processing conditions such as ingot composition, part manipulation and EB energy, EB-PVD technology is capable of deposit various coatings:
1. Functional gradient coatings
2. Multilayered thick ceramic coatings
3. Textured multilayer coatings
4. Biological coatings
5. Hot Corrosion & Oxidation Resistant Coatings
6. Uniform Thermal Barrier Coatings (TBCs)
7. Damping and Wear Resistant Coating
8. Thick Repair Coatings up to 1-2 mm
Difference between plasma spray and EB-PVD:
Next gen TBC validated by the DRDL for the Scramjet Engine:
continued....
Thread:
Thermal barrier coating Thermal barrier coating is the one key technology for our upcoming fighter jet engine. Thermal barrier coating (TBC) is a protective layer applied to metallic components to shield them from extreme heat and harsh conditions.
The two primary methods for applying thermal barrier coatings (TBCs):
1. Plasma spray.
2. Physical Vapor Deposition (PVD)
Plasma spray: Plasma spray is a thermal spraying process that uses a high-temperature plasma jet to melt and coat a surface with various materials.
Physical vapor deposition (PVD): PVD is a technique that uses physical processes to create thin films on surfaces. It's also known as thin-film coating. DMRL and ARCI. Both are together working on thermal barrier coating.
EB-PVD unit developed by DMRL and ARCI:
Advantages of EB-PVD:
1. Coatings obtained are dense, uniform and smooth
2. Deposition rates a high as 50-100 pm/min.
3. productivity of 10-15 kg/hr possible.
4. Large window of coating thickness (10pm-2 mm).
5. Ability to coat thin foils, strips, sheets & heavy blanks.
APPLICATIONS OF EB-PVD COATINGS: By changing the processing conditions such as ingot composition, part manipulation and EB energy, EB-PVD technology is capable of deposit various coatings:
1. Functional gradient coatings
2. Multilayered thick ceramic coatings
3. Textured multilayer coatings
4. Biological coatings
5. Hot Corrosion & Oxidation Resistant Coatings
6. Uniform Thermal Barrier Coatings (TBCs)
7. Damping and Wear Resistant Coating
8. Thick Repair Coatings up to 1-2 mm
Difference between plasma spray and EB-PVD:
Next gen TBC validated by the DRDL for the Scramjet Engine:
continued....
continued from above...
TBC coated Turbine blade:
The standard thermal barrier coating material is yttria-stabilized zirconia (YSZ):
Key Properties of yttria-stabilized zirconia (YSZ):
High Ionic Conductivity: Used in solid oxide fuel cells (SOFCs) and oxygen sensors.
Thermal Stability: Withstands high temperatures, making it ideal for thermal barrier coatings in jet engines and gas turbines.
Mechanical Strength: Tougher than pure zirconia, used in dental implants and wear-resistant components.
Corrosion Resistance: Resistant to harsh chemical environments.
Structure of thermal barrier coating
TBC coated Turbine blade:
The standard thermal barrier coating material is yttria-stabilized zirconia (YSZ):
Key Properties of yttria-stabilized zirconia (YSZ):
High Ionic Conductivity: Used in solid oxide fuel cells (SOFCs) and oxygen sensors.
Thermal Stability: Withstands high temperatures, making it ideal for thermal barrier coatings in jet engines and gas turbines.
Mechanical Strength: Tougher than pure zirconia, used in dental implants and wear-resistant components.
Corrosion Resistance: Resistant to harsh chemical environments.
Structure of thermal barrier coating