Part 6: Technology Race - Combat Weapons Military Technology Developments
The full spectrum of "Military Technology" encompasses a wide range of combat systems, which also includes "Space Systems, Missile Systems and Drone Systems" that have been covered in the earlier papers. The scope of this paper is restricted to technologies of combat systems considered most critical in air, land and sea domains.
The Technology Race - Basic Facts
Winners in the technology race depend on who innovates fast. Innovation depends on research and development (R & D). In turn, R & D depends on education infrastructure, high-tech faculty and budget allocation for R & D.
Ipso facto, the emerging military technology developments are extraordinary hi-tech, high cost, complex and secretive arena of strategic competition at global level with regional powers also joining the race. Mutual interdependencies are inevitable. The country that manages them pragmatically wins the technology race in combat weapons systems and wars.
"Wars" are classified under the terminology of "Generations - GEN" for analysis to include: GEN I (1648-1860); GEN II (1860-1918), GEN III (Post World War 1 and World War 2) and GEN IV or + (Post World War 2). Post Gulf War in 1993, Revolution in Military Affairs (RMA) and Network-Centric War got coined in military terminology. The ongoing conflicts are classified as Hybrid Wars or GEN V warfare covering multi dimensional fields to include influence and cyber warfare and artificial intelligence (AI).
At the global level, the competition in the military technology race - GEN IV + and GEN V and even Gen VI - is between the USA and China. At the regional level, India's competition in military technology is not only with China, but also with Turkey, Iran and Pakistan. Although India started ahead of China in the 1950s by establishing R & D infrastructure, it now lags behind in GEN IV + OR V combat systems. China has made rapid breakthroughs and significant gains driven by centralized strategic planning and massive government spending. By contrast, frittering away of resources over 80 R & D agencies (50 DRDO and 15 DoAE, etc.) and phenomenal delays in timely deliveries are real.
Political decision making - poor prioritization - is responsible for frittering away budgetary allocations due to lack of understanding the basics of combat systems. And, "Brain Drain" continues.
Aero Jet Fighter Engines
Aero space dominance is most critical to win wars. Aero jet fighter engines capability is most critical for high speed, pay loads and maneuverability. Most important, aero engines for "Stealth Fighter - GEN V" in service in the USA, China and Russia have very high thrust-weight ratio engines. And, the GEN V+ and GEN VI fighters are under development. Due to requirement of operating with "Drone Swarms", highly sophisticated C⁵I (Command, Control, Communications, Computers, Cyber and Intelligence) system is the emerging aerospace battle scenario that adds weight to the aircraft. India is at least 10 to 15 years behind other air forces, particularly the USA, China, Russia, France, Germany, EU and Japan.
Where does India stand in the aero jet fighter engines technology? In 1959, the Gas Turbine Research Establishment (GTRE) was established to develop the "first centrifugal type 10 kN thrust engine". Over two decades later in 1973, the redesigned and developed "1700K reheat system" for the Orpheus 703 engine was certified and successfully upgraded the Orpheus 703 to 2000K. It powered the HAL HF-24 Maruti fighter-bomber, which was the first Asian jet fighter - 1 April 1967 well before Chinese.
Ipso facto, Jet engine design, development, production, operation, and support are complex activities. The design of safe, affordable, and reliable jet engines requires the integration of many technical disciplines, including aerodynamics, thermodynamics, fluid mechanics, solid mechanics, materials development, fuels research, combustion systems design, heat transfer analysis, and controls development. Are IITs and other institutions of excellence providing the requisite expertise to students?
Most importantly, India lacks the manufacturing capability to produce Nickel based super alloys, Titanium, molybdenum, rare earth elements like yttrium, niobium, tantalum, ruthenium, and hafnium that are used in jet engines particularly for the turbine blades and turbine disks. Yet another constraint was lack of engine testing infrastructure necessitating the test engines to be flown to Gromov Flight Research Institute, Moscow.
Followed the design and development of a "demonstrator" gas turbine engine—GTX 37-14U. Only in 1986, the GTRE launched a program to take up turbofan design and develop an indigenous power plant for the Light Combat Aircraft (LCA) - designated the GTX-35VS "Kaveri". Even after 46-years of R & D, GTRE failed to produce desired results for the LCA Tejas and its variants. The current Kaveri engine thrust capability is 72 kN. Under consideration is to develop an upgraded Kaveri engine with 90 KN thrust with French cooperation which can eventually be used for Tejas Mk 2. Presently, the imported US F404 IN20 engine, generating 84kN, thrust powers Tejas Mark 1 and Mark 1A variant. US GE F414 INS6 engine, generating 98 KN thrust, will power Tejas Mark 2.
By contrast, in the USA, the engines currently in use include: the F135 (125 kN) military thrust and 191 kN with afterburner, “invisible” to detection, the most powerful and most advanced fighter engine ever produced; Pratt F119 (116 kN) military thrust and 156 kN with afterburner that powers the F-22 fighter; F110-GE-132 that power F-16 Block 60 (85 kN) military thrust and 145 kN with after burner. Whereas, Su-30MKI is powered by Russian AL-31FP turbofans, rated at 123 kN with after-burner thrust. Russia Izdeliye 177 (AL-41F1) produces 147 kN afterburner thrust. And, Chinese WS-10G – J-20 - generated 152–155 kN thrust; and WS-15 achieved 160 kN with afterburner.
Meanwhile, the US present R & D program is to develop revolutionary new power plants from the Adaptive Engine Transition Program (AETP) - the XA100 from GE Aviation and the XA101 from Pratt & Whitney. Both say their engines yield 25 to 30 percent more range; up to 18 percent greater acceleration; and increased cooling capability for onboard electronics. Potential other benefits include more electricity to power emitting systems and directed-energy weapons, and a reduced heat signature to improve stealth.
Yet another significant issue to be noted is Tejas Mk 1 squadron became operational in 2016. The second Tejas squadron with Tejas Mk 1 was formed on 27 May 2020. In February 2021, Rs 46,898 crore contract for 73 “improved” Mark-1A fighters and 10 trainers, which are set to enter service in February 2024 and end by February 2029 with the production rate of 18 aircraft per year. HAL plans to use its underutilized Nasik facility to further augment its production capacity.
Flyable Tejas Mk II, GEN IV +, with supercruise capability and more powerful 98 kN thrust based on GE F414 engine, is yet to roll out. The realistic first flight time-line would be 2028. The aircraft may be inducted around 2034-35. If so, the first Tejas Mk 2 is likely to enter service by 2036. Today, the Tejas Mk 2, rebadged as the Medium Weight Fighter or (MWF), is a replacement for the Mirage 2000.
Finally, the "Critical Design Review" of GEN V fighter jet (AMCA) - a 25-tonne, twin-engine stealth fighter jet with an internal weapons bay - will be soon submitted for approval from the Cabinet. “Once the project sanction is received, the first prototype can be rolled out in three years and the first flight in one to one and half years after that”, as per AMCA project director AK Ghosh at the recently concluded DefExpo 2022. If so, the first GEN V fighter jet prototype will take flight by 2028.
Key Land Forces combat systems
Similarly, the development of key land forces combat systems have been plagued by delays. The first indigenous Vijayanta Battle Tank - GEN II - that entered service in 1965 was phased out by 2008. Arjun - GEN III Tank - whose design started in 1986 finished 10 years later in 1996 entered service 2004 and that too for limited production. As on date, the plan is to develop Next Generation Main Battle Tank (NGMBT) or Future MBT (FMBT) for network-centric battlefield environs. All over again, China, albeit late starters, has overtaken India with the production of T-99 that figures in the Top Ten tanks in the world and also their Type 15 Light Tank for the High Altitudes. Of late, India has caught up with fielding artillery gun systems on par with the Chinese systems, but lag behind in rockets and missiles.
Ironic, but true, the DRDO has failed to indigenously produce even pistols, sub machine carbines, assault rifles, machine guns, grenade launchers and mortars. Glock and Beretta P X 4 pistols are imported from Austria and Italy for Special Forces. SMGs are imported from Israel, Germany, Switzerland and the UK. AK 203 from Russia based on transfer of technology is yet to commence production. The wide range of assault rifles are imported from the USA, Israel, Belgium, Taiwan, Bulgaria and others. Machine guns are imported from Belgium, Israel and the USA. To sum up, India lags behind in many land forces combat weapon systems technologies.
Seas particularly Aircraft carriers and Submarines
With over five decades of indigenization in the field of design and construction of warships, the Indian Navy (IN) has embarked upon a plan to achieve self-reliance in the design and manufacture of high–tech defense equipment. The plan has been articulated through a guideline document titled “Indian Naval Indigenization Plan (INIP) 2015-30”, The document covers all aspects of the naval equipment including Marine engineering equipment; Electrical and electronic systems; Weapon, armament and sensors; Submarine equipment and systems; Aircraft handling equipment; Diving and special operations equipment; Naval aviation equipment and future technologies. The rapid developments in the field of defense electronics, ammunition and data processing are continuously reinventing the nature of the threats to naval platforms
In the "Float" category - all materials, equipment and systems associated with the hull structures and fittings - 90 per cent indigenization has been achieved. In the "Move" category, 60 per cent indigenization has been achieved. And, in the "Fight" category, 30 per cent indigenization has only been achieved.
Currently 48 state-of-the-art ships and submarines are under construction in government and private shipyards. Across radar, sonar, radio, microwave and satellite technology, IN also operates some of the world's most sophisticated surveillance and intelligence gathering systems, to identify threats and maintain strategic superiority.
If so, IN lags behind China even in the "Move and Fight" categories particularly in Anti-Ship Missile Defence - a mix of quick–reaction high performance surface-to-air missile (SAM) systems, high rate of fire close-in weapon system (CIWS) guns and, in future, the employment of directed energy weapons (DEW); Attack and Fire Support Missions - by precision cruise and sea-skimming missiles launched from ships, submarines with a longer range, be stealthier, faster, and smarter with better electronic counter countermeasures capabilities, and aircraft anti-ship missiles, land-attack missiles and thus suitable caliber guns with extended range guided munitions projectiles for larger caliber (127mm, 155mm and even larger) guns to be developed/procured and Vulcano ammunition family which is based on sub-caliber with the guided version having aerodynamic controls and INS/GPS navigation. Also, electro-magnetic (EM) "Rail Gun" and Directed Energy Weapons (DEWs), Laser Weapons, Underwater Torpedoes and underwater smart mines to be launched from air also.
Finally, India needs to import semiconductor chips, the mainstay of advanced avionics, digital Fly-By-Wire (FBW) controls, multifunction active electronically scanned array (AESA) radars, helmet-mounted sights (HMDS), improved secure and jamming-resistant data-links, super-cruise ability and BVRAAM missiles etc., for even GEN 4.5 fighters. Also, capability for 360 degrees situational awareness in GEN 5 aircraft among many others.
To sum up, India lags behind by at least 10 to 15 years in developing combat weapon systems in Air, Land and Sea domains to wage GEN V wars. Even now, aero jet engines for Tejas Mk 2 are imported from the USA. Similarly, over 50 per cent of current military technologies for combat weapon systems are imported from other countries. High time for the policy decision makers in conjunction with R & D agencies to review and determine priorities and accordingly allot appropriate budgets. Also, there is a need to review and close non-performing units and mergers to optimize budget allocations.
Article by G B Reddy Sir
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