Fasteners, Fluids & Gaskets

The tailfin for the LCA is a monolithic honeycomb piece, an approach which reduced its manufacturing cost by 80% compared to the customary "subtractive" or "deductive" method, whereby the shaft is carved out of a block of titanium alloy by a computerized numerically controlled machine. more...

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No other manufacturer is known to have made fins out of a single piece. A 'nose' for the rudder is added by 'squeeze' riveting.

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.

The airframe of the naval variant of the Tejas will be modified with a nose droop to provide improved view during landing approach, and wing leading edge vortex controllers (LEVCON) to increase lift during approach. The LEVCONs are control surfaces that extend from the wing-root leading edge and thus afford better low-speed handling for the LCA, which would otherwise be slightly hampered due to the increased drag that results from its delta-wing design. As an added benefit, the LEVCONs will also increase controllability at high angles of attack (AoA).

The naval Tejas will also have a strengthened spine, a longer and stronger undercarriage, and powered nose wheel steering for deck manoeuvrability. The Tejas trainer variant will have "aerodynamic commonality" with the two-seat naval aircraft design.

Landing gear

The Tejas has a hydraulically retractable tricycle-type landing gear with a pair of single inward-retracting mainwheels and a steerable, twin-wheel forward-retracting nose gear. The landing gear was originally to have been imported, but following the imposition of trade sanctions, HAL developed the entire system independently.

India's Nuclear Fuel Complex (NFC) led the team that developed the titanium half-alloy tubes that are used for hydraulic power transmission and they are critical components in the LCA. India is one of only six nations which have developed this technology, which also has space applications.

Flight controls

Since the Tejas is a "relaxed static stability" design, it is equipped with a quadruplex digital fly-by-wire flight control system to ease handling by the pilot. The Tejas' aerodynamic configuration is based on a pure delta-wing layout with shoulder-mounted wings. Its control surfaces are all hydraulically actuated. The wing's outer leading edge incorporates three-section slats, while the inboard sections have additional slats to generate vortex lift over the inner wing and high-energy air-flow along the tail fin to enhance high-AoA stability and prevent departure from controlled flight. The wing trailing edge is occupied by two-segment elevons to provide pitch and yaw control. The only empennage-mounted control surfaces are the single-piece rudder and two airbrakes located in the upper rear part of the fuselage, one each on either side of the fin.

Read more at Wikipedia.org