Over the last three decades, CSIR-National Aerospace Laboratories (CSIR-NAL), Bengaluru, has developed many critical technologies for the Light Combat Aircraft (LCA) Tejas and continues to support this majornational programme. 

Composites offer an attractive option in modern aircraft development as they are lighter, have better mechanical properties, and are fatigue insensitive and corrosion resistant as compared to aluminum alloys. Composite structures in LCA contribute 45% by weight making it one of the world’s smallest light weight fighter aircraft.

Dr K.N. Raju, former Director, CSIR-NAL, successfully led the national team for composite wing development. The Advanced Composites Division (ACD) has pioneered the design & development of composite structures using innovative and cost-effective manufacturing technologies including co-curing/co-bonding constructions. ACD-NAL has played a pivotal role in the development of the Fin & Rudder, Wing Spars, Wing Fuselage Fairings, Fairings blocks, Centre Fuselage parts & Undercarriage doors. The innovative technologies developed by CSIR-NAL not only reduce the cost but also improve structural efficiency by minimising the number of mechanical joints. The innovations have resulted in more than 20% savings in cost and 25% reduction in weight. 

CSIR-NAL has a tie-up with Tata Advanced Systems Ltd (formerly TAML), for the supply of critical CFC components for the series production of LCA. Supply of critical components has been completed for the first batch of 20 aircrafts (SP1-20) to IOC standard in 2019 and supply of components to FOC standard is under progress for the next batch of 20 aircrafts (SP 21-40) and is expected to be completed by October 2022.

ACD-NAL has handheld TASL and ensured that parts have been delivered meeting the stringent timelines. The entire quality assurance support for the above programmes has been provided by NAL. As TASL has now matured as a production partner, HAL, in collaboration with NAL, has directly placed a PO on TASL for further supplies for a value of Rs220 crores. Furthermore, HAL has requested for transfer of technology for the Fin & Rudder and the proposal by NAL is awaitingapproval from HAL Board.

Recent Success

In recent discussions between HAL & CSIR-NAL, the former has desired the direct sourcing of CSIR-NAL developed 15 (fifteen) composite partsfor LCA Mk1A from the production partner TASL tofulfil timely deliveries to the Indian Air Force (IAF) for meeting the strategic needs of the country. Under the MoU signed during the years 2008 & 2009, TASL has successfully absorbed the know-how for the production of critical composite parts & delivered partsto HAL for 20 LCA aircraftsto IOC standards and components for the next batch of 20 LCA aircraftsto FOC standards is under progress under the quality coverage of CSIR-NAL.

In this backdrop, CSIR-NAL & TASL under the agreement signed on 12 July 2022 have agreed that HAL can directly place purchase orders on TASL for procurement of 15 composite parts for the initial order of 42 sets for LCA Mk1A aircraft. Upon signing of the agreement, CSIR-NAL has issued authorisation to HAL for direct sourcing of the composite parts from its production partner i.e. TASL for LCA Mk1-A under intimation to CSIR-NAL. 

For the supplies to be made by TASL based on the know-how of CSIR-NAL, TASL will pay a royalty of 7% of the cost of the PO for the first 50 sets of LCA Tejas Mk1A and 5% thereafter. Furthermore, it is to be noted that even after completion of PO, NAL will continue to receive royalty as long as TASL /HAL make LCA-Tejas aircraft.CSIR-NAL is happy to share that the above agreement has resulted in placing a purchase order by HAL on TASL for sourcing of CSIR-NAL developed 15 composite parts for the LCA MK1A vide HAL purchase order of 10 August 2022. 

Direct Benefits

•    The PO by HAL on TASL is ofthe value of Rs 220 crores which is the highest value of order received by any CSIR-NAL industry partner in the recent past.
•    For the orders received by TASL from HAL, CSIR-NAL will be receiving a royalty payment of about Rs 13 crores.
•    Earlier PO value ofIOC is about Rs 59 crores and FOC is Rs 84 crores.
•    Total value realised by NAL as on date,Rs 129 crores.

Other Benefits
The composite manufacturing technologythat has been developed by CSIR-NAL during the technology denial regime hashelped the country to develop 4+ generation fighters. This has led to India being one of the top seven countries with the capability to design, develop and produce a world-class fighter thus saving huge foreign exchange for the country from imports of LCA class aircraft. It would be apt to state that without these weight reduction technologies, LCA might never have taken to the skies!

Acknowledgements

CSIR-NAL wishes to acknowledge & place on record support received from CSIR, former Directors of CSIR-NAL, HAL & TASL team.