Lok Sabha Question No. 1061 (UNSTARRED), answered on 2023-02-08
Subject: National Aerospace Laboratories
Ministry: SCIENCE AND TECHNOLOGY
Asked by: Amol Ramsing Kolhe

## GOVERNMENT OF INDIA MINISTRY OF SCIENCE AND TECHNOLOGY

## DEPARTMENT OF SCIENTIFIC AND INDUSTRIAL RESEARCH LOK SABHA

UNSTARRED QUESTION NO. 1061 (TO BE ANSWERED ON 08.02.2023)

## NATIONAL AEROSPACE LABORATORIES

1061.  DR. AMOL RAMSING KOLHE:

Will the Minister of SCIENCE AND TECHNOLOGY be pleased to state:

- (a) the  details  of  the  number  of  National  Aerospace  Laboratories across the country, State/UT-wise including Maharashtra;
- (b) the details of the funds sanctioned, allocated and utilized by these laboratories  during  the  last  three  years  and  the  current  year, State/UT-wise including Maharashtra;
- (c) the  details  of  the  target  set  and  achievements  made  by  these laboratories during the above-said period; and
- (d) whether the Government is planning to develop drones or Unmanned Aerial Vehicles (UAVs) by these laboratories; if so, the details thereof and if not, the reasons therefor?

## ANSWER

MINISTER OF STATE (INDEPENDENT CHARGE) OF SCIENCE AND TECHNOLOGY & EARTH SCIENCES

(DR. JITENDRA SINGH)

- (a) CSIR-National  Aerospace  Laboratories  (CSIR-NAL),  Bengaluru,  a constituent  laboratory  of  the  Council  of  Scientific  &  Industrial Research (CSIR) is the only  public  funded  and  civilian  aerospace R&D laboratory in the country.

- (b) The details of the funds sanctioned, allocated and utilized by CSIRNAL for the last three years and current year are as under:

(Rs. in crore)

| Financial Year   | Sanctioned/   | Utilized   |
|------------------|---------------|------------|
|                  | Allocated     |            |
| 2019-20          | 237.84        | 237.84     |
| 2020-21          | 236.26        | 236.26     |
| 2021-22          | 283.75        | 283.75     |
| 2022-23          | 386.77        | 232.96*    |

*Utilized as on 31.12.2022

- (c) CSIR-NAL's  mandate  is  to  develop  aerospace  technologies  with strong science content, design and build small, medium sized civil aircraft,  and  support  all  national  aerospace  programmes.  The laboratory target is  to  take-up  and  implement  major  aircraft programmes  like  two-seater  flying  trainer  (Hansa-NG),  Multi-Role Light  Transport  Aircraft  (19  seat  SARAS-MkII),  and  the  Regional Transport  Aircraft  (RTA)  to  enhance  the  air  connectivity  under Govt. of  India's  UDAN  scheme.  The  aircraft  programs  aim  to meet  the country's civil aviation requirements and to synergize the multidisciplinary expertise of the laboratory meeting the objectives of Atmanirbhar Bharat.

Further, the endeavor of the laboratory is to support major national aerospace  programmes  of  Indian  Space  Research  Organisation (ISRO) & Defence Research and Development Organisation (DRDO). The  laboratory  is  being  continued  to  support  the  major  national aerospace  programmes  notably  the  Light  Combat  Aircraft  (LCA)Tejas  of  Aeronautical  Development  Agency  (ADA);  satellite  & launch  vehicle  programmes  of  ISRO;  and  missile  programmes  of DRDO.  CSIR's  developmental  work  in  strategic  areas  has  helped the country in overcoming the technological denial regimes especially  ADA's  LCA-Tejas  programme  with  critical  technology inputs like composite air frame parts and fly-by-wire control laws

etc., Additionally, it has helped to protect confidentiality of strategic data and enhanced the nation's prestige in the international arena.

The significant achievements/contributions of the laboratory during the last three years and the current year is at Annexure-I.

(d) Yes,  Sir.    CSIR-NAL  has  developed  medium  class  Beyond  Visual Line  of  Sight  (BVLOS)  multi-copter  Unmanned  Aerial  Vehicles (UAVs).  The brief details are at Annexure-II.

********

## Annexure-I

## Significant Achievements of CSIR-NAL during the year 2019-2020

## Contributions to the Civil Sector

-  During the year, considerable progress was achieved in the design of SARAS Mk-2 (19 seater aircraft) towards optimization of configuration. The drag reduction and aerodynamic efficiency, reduction  in  Operating  Empty  Weight  (OEW)  and  increase  in  useful load,  improvements  in  Flight  Control  System  (FCS)  and  general systems were addressed. Significant progress was  made  with preliminary layouts, preliminary configuration documentation, Computational  fluid  dynamics  (CFD)  analysis,  wind  tunnel  testing, configuration design, performance estimation, stability and controllability and critical load cases for structural design has been achieved for SARAS Mk-2 aircraft.
-  Significant  efforts  were  made  towards  the  development  of  HansaNew  Generation  (NG)  aircraft  with  the  improvements  such  as  allglass  cockpit,  advanced  fuel  efficient  Rotax  912iSc  engine  with better  performance  (increased  range  and  endurance),  optimized airframe, steerable nose wheel, electrically operated flaps, Instrument  Flight  Rules  (IFR)  compliance,  improved  ingress-egress, better interiors/ergonomics and external finish. The new power plant system  installation  along  with  proposed  aerodynamically  efficient cowling to suit the Rotax 912iSc 3 Sport engine has been designed. Fuel system and engine thrust measurement test rigs were developed and  realized  to  test  the  engine  performance  on  ground.  Design changes were incorporated in the cockpit for the installation of full Glass-cockpit MIP with improved aesthetics and ergonomics.
-  CSIR-NAL's  Drishti  crossed  more  than  century  mark  -  105  systems working  in  21  Civilian  International  Airports  (51  systems)  and  18 Indian  Air  force  airbases  (54  systems).  Kempegowda  International Airport (KIA), Bengaluru, had the honour of getting the 50 th  system in November  2019  -  a  golden  land  mark  for  Civilian  Airports  when  4 Drishti systems were installed in the new Runway of KIA.

-  CSIR-  NAL  has  successfully  designed  and  developed  various  multicopters  for  different  applications.  The  developed  Multi-copters  are 0.5 Kg payload Quad-Copter, 5.0 Kg Payload Hex-Copter and 20.0 Kg Payload Octa-Copter. The developed Quad-Copter is extensively used in  acquiring  Arial  Multi-Spectral  images  of  selected  medicinal  and aromatic  crops  covering  1,99,754  m2  area  maintained  by  CSIRInstitute of Himalayan Bioresource Technology (CSIR-IHBT), Palampur. Successful flight trials for the Octa-Copter carrying payload  either  hyper  spectral  camera  or  pesticide  sprayer  were completed.  For  the  first  time  in  the  country,  Drone  based  Earth Magnetic field survey was conducted by joint team of CSIR-NGRI and CSIR-NAL.  In  this  flight  campaign,  the  magnetometer  AirBird  is integrated as a slung load to the NAL Hex-Copter. The results of the drone based survey are compared with other methods and found that the drone based magnetic survey data is consistent and reliable.

## Contributions to Strategic Sector

-  CSIR-NAL's National Trisonic Aerodynamic Facility has completed 1632 blowdowns in the 1.2m and 629 blowdowns in the 0.6m wind tunnels. The major users of the facility were Defence Research and Development Organisation (DRDO), Indian Space Research Organisation  (ISRO)  and  CSIR-NAL.    For  Defence  Research  & Development Laboratory (DRDL), wind tunnel tests were conducted for  full  scale  model  of  missile  configuration  to  obtain  the  basic aerodynamic characteristics and control effectiveness.
-  Continued  support  to  the  ADA's  LCA-Tejas  Programme.  CSIR-NAL continued to make contributions in the areas of design, fabrication and R&D of composite structures.
-  CSIR-NAL has significantly contributed to flight mechanics parameter  analysis  and  controller  design for  unmanned aerial vehicle (UAV) - unmanned combat aerial vehicle (UCAV) program. Performance verification of the flight control laws was carried out in the nonlinear simulation environment  to  ensure  the  flight worthiness of the flying wing UCAV.

-  34 investigations involving incidents/ accidents of aircraft, helicopters and ground equipment used for defence aircraft were referred to the laboratory for investigation by the various organizations  like  Indian  Air  Force  (IAF),  Hindustan  Aeronautics Limited (HAL) & Ministry of Civil Aviation (MoCA). In most of these investigations, the primary cause(s) of failures could be identified and after each investigation, recommendations were suggested for prevention of similar incidents/accidents in future.

## Contributions to Space Programmes

-  The Indian Space Programme has been ably supported by the CSIRNAL's  Acoustic  Test  Facility  (ATF)  over  the  last  three  decades. Acoustic  qualification  of  space  bound  hardware  has  been  very crucial  to  ensure  the  reliability  of  the  hardware  and  successful completion of the mission. ATF carried out a major acoustic test programme on four numbers of  the  L40  Strapon  Nosecone  decks for the F10 mission of the GSLV-MKII in addition to acoustic tests on  the  PSLV-PS4  Flexible  Solar  Panel.  ATF  also  successfully completed  acoustic  test  programmes  on  two  subsystems  of  the new Small Satellite Launch Vehicle (SSLV) of ISRO during the year. ATF  completed  the  design,  fabrication,  testing  and  supply  two numbers of high intensity  octave  band  microphone  calibrators  to the  Vikram  Sarabhai  Space  Centre,  Thiruvananthapuram  and  one calibrator to Satish Dhawan Space Centre (SHAR) of ISRO. Various units  of  ISRO  require  such  calibrators  for  use  in  calibration  of microphones used in satellite launch missions.
-  Wind  tunnel  tests  conducted  for  Vikram  Sarabhai  Space  Centre (VSSC)  include  aerodynamic  characterization  of  various  launch vehicles and Crew Escape System (CES) test vehicle configuration for  the  ambitious  Gaganyaan  project.  The  wind  tunnel  tests involved various types of measurements such as force, steady and unsteady  pressure  measurements  in  the  0.6m  and  1.2m  trisonic wind tunnels. Various scaled down models for Crew Module (CM), Crew  Escape  System  (CES)  and  CES  test  vehicle  configurations were also designed for Gaganyaan SSLV projects.

## Special Materials Development

-  CSIR-NAL has made significant contributions in the area of special materials.  The  laboratory  has  taken  up  collaborative  R&D  work with Sree Chitra Tirunal Institute for Medical Sciences and Technology (SCTIMST), Trivandrum for development of three specific  products,  viz.,  (i)  Aortic  Stent  Grafts  (ASG),  (ii)  Atrial Septal Defect (ASD) occluder and (iii) flow diverter. These endovascular implants have been developed for minimally invasive treatments of aneurysms in thorax, brain and for closure of atrial septal defect respectively.
-  A  GMHLT  -  XX  series  Hydrostatic  Level  Transmitter  has  been developed  based  on  GMR  technology.  The  sensor  is  designed  in both digital and analog interface with a wide operating range from 1.5 m to 10 m of liquid level. M/s Filpro Sensors Pvt. Ltd, Bangalore have  evaluated  few  sensor  prototypes  and  given  satisfactory remarks.
-  A  process  technology  on  the  'Development  of  an  Electrolyte Formulation for  Electro  polishing  of  Stainless  Steel  Needles'  has been transferred to M/s Sutures Ltd., Bangalore for surgical needle applications on 25th September 2019. Polished needles have been
- handed over to cancer care India.

## Societal Mission Activities

-  CSIR-NAL  continued  the  dissemination  of  1  kW  wind  solar  hybrid (WISH)  systems  to  S&T  institutions  in  and  around  Bengaluru  and demonstration  of  10  kW  systems.  The  commitments  towards  an important  public  outreach  program  of  CSIR,  namely  the  Mass Housing project were successfully met through the installation of WiSH  systems  at  CSIR-SERC,  Chennai  and  CSIR-CBRI,  Roorkee, Uttarakhand. The other achievements include the installation of a roof-top 1 kW class WiSH system at the Parala Maharaja Engineering College in Berhampur, Odisha. Keeping pace with the latest Internet of Things (IoT) technology, the data acquisition and

## monitoring  of  NAL's  WiSH  systems  have  been  WiFi  and  internetenabled.

## Significant Achievements of CSIR-NAL for the year 2020-2021

## Contributions to the Civil Aviation Sector

-  Preliminary Design Review (PDR) of Saras Mk2 19 seater aircraft has been  completed.  In  the  process  of  optimizing  the  configuration, various intermediate versions were studied through several Computational  fluid  dynamics  (CFD)  and  wind  tunnel  campaigns. Performance  and  stability-control  characteristics  of  the  aircraft were also evaluated at every step. Constant effort has been made to develop the simulator simultaneously and aero-data is updated and evaluated  by  pilots  at  regular  intervals.  Air  loads  were  estimated using  CFD  for  structural  analysis.  Feasibility  of  operations  at  high altitude  airfields  like  Leh,  Kargil,  Shimla,  Kulu  and  Pakyong  were studied and optimized for higher load factor. Cabin thermal analysis was  carried  out  and  oxygen  requirement  was  fulfilled  for  such operation.
-  CSIR-NAL  has  obtained  Design  Organization  Approval  (DOA)  and Production  Organization  Approval  (POA)  under  CAR  21  subpart  G from  Directorate  General  of  Civil  Aviation  (DGCA)  to  carry  out Hansa-NG  design  and  production.  Fabrication  and  assembly  of  all airframe  and  system  components  are  completed.  Static  testing  of Air  Frame  has  been  completed  successfully.  Engine  ground  runs were carried out successfully.
-  With  the  installation  of  CSIR-NAL's  Aviation  Weather  Monitoring System (AWMS), at Kempegowda International Airport (KIA), Bengaluru,  the  KIA  has  become  the  first  airport  in  the  country  to install indigenous AWMS technology, developed by CSIR-NAL at both ends of the new runway. In addition, KIA has installed four Drishti transmissometers and has the unique honour of having NAL's 50th Drishti  installed  at  its  runway.  KIA  now has  a  total  of  six  Made  in India RVRs at both runways.

-  Vibration  measurement  is  the  most  essential  requirement  at  low frequency  excitation  which  is  commonly  used  for  overall  health management of the aircraft. Piezoelectric (PE) accelerometers are widely used for vibration measurements for structural testing, flight testing  and  inflight  vibration  monitoring.  Considering  the  in-house requirements,  a  ruggedized  version  (Prototype-2)  of  Piezoelectric (PE) accelerometer that suits the above requirements was designed and developed during this period. The developed accelerometer has been  tested  on  SARAS  PT1N,  was  calibrated  with  inflight  data acquisition system and has passed environmental tests and received  National  Accreditation  Board  for  Testing  and  Calibration Laboratories (NABL) accreditation.

## Contributions to Strategic Sector

-  CSIR-NAL's  National  Trisonic  Aerodynamic  Facility  has  completed 1028 blowdowns in the 1.2m and 254 blowdowns in the 0.6m wind tunnels during the year. The major users of the facility were Defence Research  and  Development  Organisation  (DRDO),  Indian  Space Research  Organisation (ISRO) and CSIR-NAL. For Aeronautical Development Agency (ADA), wind tunnel tests were conducted on a typical  combat  aircraft  configuration  on  the  basic  aerodynamic
- characteristics.
-  CSIR-NAL continued its support to the LCA-Tejas Programme. CSIRNAL  continued  to  make  contributions  in  the  areas  of  design, fabrication and R&D of composite structures.
-  For  the  Advanced  Medium  Combat  Aircraft  (AMCA)  program  High Cycle  Fatigue  (HCF)  data  was  generated  for  the  indigenously developed  Titanium alloy Beta21S  (Titan 44A) material  which intended to be used in AMCA airframe structural applications in high temperature  zones.  Ground  Vibration  Testing  (GVT)  based  flutter analysis  and  store  separation  studies  carried  on  Mirage  2000 aircraft. Further, GVT and GVT Based Flutter Analysis of Su-30 Mk-I Aircraft  for  Derby  Integration  was  addressed  and  clearance  was provided  for  captive  trials  as  part  of  the  DOS-30  (Derby  on  Su  30) programme.  A  total  of 20 configurations were  considered  for

- clearance.  Global  elastic  modes  of  the  aircraft,  store  modes  and
- control surface modes were analyzed and tabulated.
-  A compact version of the MZHB that houses the accessories inside the  equipment  case  was  developed  with  wheels  for  ease of transportation.  The  MZHB  facility  was  extended  to  Light  Combat Aircraft  (LCA)  program  for  the  repair  of  drop  tank  and  engine  bay cover.
-  During the year 2020-21, sixteen investigations involving incidents/ accidents  of  aircraft,  helicopters  and  ground  equipment  used  for defence aircraft were referred to the laboratory for investigation by the  various  organizations  like  Indian  Air  Force  (IAF),  Hindustan Aeronautics  Limited  (HAL)  &  Ministry  of  Civil  Aviation  (MoCA).  In most of these investigations, the primary cause(s) of failures could be  identified  and  after  each  investigation,  recommendations  were suggested  for  prevention  of  similar  incidents/accidents  in  future. Towards  contribution  of  indigenous  technology  for  the  strategic sector in stealth technology, a multi-layered FSS-based RASORBER has  been  designed  with  a  transmission  characteristic  within  the band associated with out-of-band absorption.

## Contributions to Space Programmes

-  CSIR-NAL's  Acoustic  Test  Facility  (ATF)  has  completed  acoustic qualification of Test Vehicle Equipment Bay (EB) for testing certain critical  components  of  the  Gaganyaan  Crew  Escape  system.  ATF also  qualified  the  Core  Base  Shroud  of  the  Small  Satellite  Launch Vehicle which is one of the crucial subsystems of the highly modular small satellite launcher. In addition, ATF also successfully completed  the acoustic qualification of the Strap on Electro Mechanical  Actuator  Structure  for  the  GSLV  MKIII  launcher.  This would  help  in  improving  reliability  and  also  provide  advantages  in payload capability in comparison with the Electro Hydraulic actuators used earlier.
-  Further,  unsteady  pressure  measurements  were  carried  out  on  a scaled  model  of  typical  crew  escape  system  test  vehicle  in  the CSIR-NAL's 1.2m wind tunnel. Aeroelastic testing of

Geosynchronous Satellite Launch Vehicle (GSLV) MkII F10 configurations  were  also  carried  out  at  CSIR-NAL.  A  1:42  scaled aeroelastic model of F10 vehicle was successfully designed, fabricated, and wind tunnel tested to assess the transonic buffet on the vehicle.

## Health Sector and Societal Mission

-  CSIR-NAL has made significant contributions in the area of Health and Societal Mission. The first contribution is the Personal protective  equipment (PPE)  coverall  suit  'HINDKAVACH'  for  covid19 frontline workers and the second is the 'SWASTHVAYU' a noninvasive  BiPAP  ventilator  for  treating  covid-19  patients.  Both  the technologies  have  been  transferred  to  industries  for  commercial production  which  has  resulted  in  quick  deployment  of  about  1500 SwasthVayu  units  to  hospitals  of  NCT-  Delhi,  Ramgarh  &  ChatraJharkhand,  Bhopal-Madhya  Pradesh,  Mysore,  Hyderabad  and  more than 2 lakhs units of PPE coverall to Hindustan Latex Limited (HLL), Jaslok Hospitals etc.
-  A cost-effective indigenous thermally compensated low-range magnetic  pressure  sensor  for  medical  ventilators,  environment friendly  sprayable  solar  absorber  coating  and  thermal  insulation paint  for  aircraft  application  has  also  been  developed  by  the laboratory.
-  With  an  increase  in  the  practical  application  of  UAV's  in  the agricultural  industry  and  to  provide  an  end  to  end  solution  in  the agricultural  domain  (from  crop  monitoring  to  pesticide  spraying), CSIR-NAL has developed a modular Oct-Copter UAV system that can carry  a  maximum  payload  of  20  Kg  and  fly  for  the  endurance  of around  20  min.  The  Oct-Copter  has  a  provision  to  house  either  a hyperspectral camera for crop health monitoring or a fertilizer. First field demonstration of NAL's Oct-Copter has been carried out for the farmers  of  Alur  Agricultural  Produce  Market  Committees  (APMC), Bangalore.

## Significant Achievements of CSIR-NAL for the year 2021-2022

## Contributions to the Civil Aviation Sector

-  The major achievement during the period was the successful maiden flight of Hansa-3 (NG) on 3rd September 2021 after obtaining special flight permit by Directorate General of Civil Aviation (DGCA). The 20minute  sortie  saw  the  first  prototype  of  the  Hansa-3  (NG)  attain  a maximum altitude of 4,000 feet and a speed of 80 knots before it made a  successful  touch  down.  Further,  the  aircraft  has  successfully completed the sea level trials at Puducherry between February 19 and March  5,  2022.  The  aircraft  was  flown  to  Puducherry,  covering  a distance  of  140  nautical  miles  in  one  and  half  hours  at  a  cruising speed of 155 km/hr, on 19 February 2022. Successful six (6) demonstration flights of Hansa-3 (NG) were performed apart from 02 ferry  flights  to  and  fro  Hyderabad  during  the  Asia's  largest  civil aviation  event  Wings  India  2022  Civil  Aviation  Jamboree  held  from 24 th -27 th  March 2022 at Hyderabad.
-  During the year, high fidelity simulator, anthropology studies, preliminary design  review,  wind  tunnel  testing,  in-board  layouts, nacelle design, Finite Element Method (FEM) structural analysis, sub system sizing, weight optimization, etc. for SARAS MK II (19 seat Light Transport  Aircraft)  were  completed.  As  part  of  facility  creation,  an Open  Air  Engine  Test  Bed  (OAETB)  has  been  reestablished.  The innovative design engineering like 3D platform, virtual reality, model based  engineering,  PLM  etc.,  are  used  to  cut  down  the  design  and production cycle time. Saras MK II (19 seat Light Transport Aircraft) Fuselage  with  Interiors,  Cockpit,  Cabin  and  ECS  System  has  been showcased at Wings India 2022.
-  Aircraft Prototype Manufacturing Facility at CSIR-NAL carried out the indigenous  manufacturing  of  air-craft  components,  metallic  tooling, wind tunnel models, certification of various subassembly and assembly  jigs.  The  major  projects  carried  out  include  extensive manufacturing  of  Metallic  components  for  Hansa-(3)  NG  aircraft, wherein  over  5000  airworthy  components  were  manufactured  apart

from  Sub-Assembly  and  assembly  jigs,  fixtures,  tooling.  Additionally, components  pertaining  to  Saras  aircraft  programme  for  Simulator, Engine Test Bed, Throttle Quadrant Box assembly, Artificial feel unit, Fuselage Interiors etc., were completed.

-  CSIR-NAL  successfully  field  demonstrated  Covid-19  vaccine  delivery by  CSIR-NAL  Octa-copter  drone  from  Chandapura  PHC  to  Haragadde PHC  at  outskirts  of  Bengaluru,  Karnataka  and  from  CSIR-Indian Institute  of  Integrative  Medicine  (CSIR-IIIM),  Jammu  to  Sub-District Hospital, Marh, Jammu.

## Contributions to Strategic Sector

-  CSIR-NAL's  National  Trisonic  Aerodynamic  Facility  has  completed 1478 blowdowns in the 1.2m (868) and in the 0.6m (610) wind tunnels during the year. The major users of the facility were DRDO, ADA, ISRO and  CSIR-NAL.  During  the  year  NAL  has  successfully  installed  and com- missioned new Wide-Angle Diffuser (WAD) replacing the 55-yearold WAD of 1.2 m tunnel. The installation work was very challenging due  to  the  size  of  the  component  and  the  required  tunnel  axis alignment accuracies.
-  CSIR-NAL  continued  its  support  to  the  LCA-Tejas  Programme.  CSIRNAL  has  made  contributions  in  the  areas  of  design,  fabrication  and R&D  of  composite  structures  for  the  LCA  programme.  A  total  of  35 shipsets  out  of  40  shipsets  were  delivered  to  HAL  by  CSIR-NAL's production  partner.  The  laboratory  is  actively  involved  in  the  EM design  and  performance  analysis  of  LCA  AF  Mk-2  Radome  towards critical  design  review  (CDR).  Under  the  control  laws  development, design of Unified Version for LCA Control LAW (CLAW) of single seater and  trainer  aircraft  was  completed  successfully  and  functionality released.  As  regards  to  Automatic  Take-off  and  Landing  (ATOL) activities on naval version of LCA  aircraft, development  of  full controller and Mode Transition Logic for ATOL demonstration, implementation and pilot evaluation in DELS was successfully completed and functionality released.

-  CSIR-NAL  has  undertaken  'Technology  Demonstrator  High  Altitude Platform (HAP) Vehicle Project' to realize a technology demonstrator research, detailed design, engineering development and manufacture of two prototypes: (a) a subscale (1:3) vehicle which would demonstrate Reynolds number equivalent flight at 3 km altitude; and (b)  a  full  scale  prototype  which  would  demonstrate  flight  of  2  hours endurance at 20 km. CSIR-NAL has demonstrated form Fit Functional Version of this HAP during Wings India 2022 Civil Aviation Jamboree held from 24 th -27 th  March 2022 at Hyderabad.
-  A  multi-layered  FSS-based  RASORBER  has  been  designed  with  a transmission  characteristic  within  the  band  associated  with  out-ofband absorption. CSIR-NAL has been recognized as the Coordinating Centre for stealth material development.
-  Laboratory  has  developed  a  novel  monolithic  RAS  technology  in collaboration with CSIR-IMMT, Bhubaneshwar. The laboratory has also developed RAM paint trade marked as ADRISHYA with very good EM absorption  properties.  This  radar  absorbing  paint  provides  a  10  dB RCS  reduction  over  a  curved  surface  in  the  frontal  sector.  The developed  RAM  paint  has  passed  all  the  environmental  &  structural tests.
-  Micro Gas Turbine (MGT) engine of 50 N thrust has been designed and developed indigenously. The engine mass flow rate is around 0.25 kg/s with exhaust gas temperature of around 820 K. The engine is intended to  power  high  speed  UAVs  and  loitering  munitions.  The  MGT  was tested for its design speed of 100,000 rpm producing thrust around 53 N. The engine was run with internal bearing lubrication circuit using a mix of Jet A1 Fuel and lube oil. The critical components of the engine are manufactured through Additive Manufacturing.
-  The  laboratory has undertaken  development  of  technologies  for Wankel  Rotary  Combustion  Engine  (WRCE)  which  include  improved wear resistance coatings for the trochoid housing and side housings of the WRCE by thermal spraying process, development of a methodology  for  the  health  management  of  the  WRCE,  research  studies  on engine noise analysis & reduction and starting system for the WRCE.

## Contributions to Space Programmes

-  During the current year, CSIR- NAL's Acoustic Test Facility (ATF) has completed acoustic qualification of Test Vehicle Base shroud, as part of  the  crew  escape  system  demonstration  programme.  The  S2V, vented inter-stage of the Small Satellite Launch Vehicle (SSLV) with the  instrumentation  decks  was  also  requalified  after  some  design changes were made in the decks to reduce the vibration input to the sensitive  packages  mounted  on  the  deck.  ATF  also  carried  out  a detailed  study  on  the  brackets  used  inside  launch  vehicle  stages  to mount  acoustic  sensors  used  to  measure  acoustic  spectrum  during flight.
-  Further, force and moment measurements on a scaled model of typical Gaganyaan  ascent  vehicle  were  carried  out  in  the  CSIR-NAL's  1.2m wind tunnel. Since it is a human rated program, it was planned to test similar configurations in various wind tunnels to verify data consistency and repeatability. The data comparison of CSIR-NAL 1.2m tunnel with other foreign tunnel was reasonably good.
-  CSIR-NAL  has  taken  up  a  project  on  aeroelastic  clearance  of  the launch  vehicle  in  various  configurations  to  experimentally  clear  the vehicle  design  from  transonic  aeroelasticity  in  order  to  ensure  the safe flight of the vehicle from transonic to supersonic regime. In the first phase, the team has successfully completed the design, fabrication, instrumentation, ground and wind tunnel testing of a 1:30 scaled aero- mechanically simulated aeroelastic model of 'GaganyaanTest Vehicle' configuration and estimated the transonic buffet on the vehicle in terms of dynamic bending moment distribution.

## Contributions to Special Materials & Coatings

-  R&D work was carried out for development of process methodology to fabricate NiTiPd high- temperature SMA wires with targeted austenite finish (A) temperature of 200±20°C. 3D-C /SiC discs (Stator and Rotor) are  made  with  aerospace  grade  carbon  fibre  with  different  fibre architectures  (3D  and  non-woven)  through  CVI.  The  dynamometer

tests  were  conducted  at  RCI,  Hyderabad  and  discs  are  found  to withstand the test conditions with lower coefficient of friction.

-  All the oxygen and NO sensors are currently imported in the country. CSIR-NAL has embarked on the indigenous development of oxygen and NOx sensing elements in collaboration with an industry. CSIR-NAL has designed  and  fabricated  the  narrowband  oxygen  sensor  that  can measure  air/fuel  ratios  between  ~14.0/15.0:1.  The  fabricated  oxygen sensor  has  exhibited  performance  equivalent  to  the  commercial oxygen  sensor  and  was  found  to  be  compatible  with  vehicle  engine control units.

Significant Achievements of the year 2022-2023 (Upto November 2022)

## Development  and  Certification  of  19  Seater  Light  Transport  Aircraft (LTA)

-  Evaluation  of  the  basic  ECS  system  functionality  of  ECS  Test  Rig commissioned at CLOCTER with existing Saras PT1N LRUs completed.
-  Review  by  DGCA  of  Design  Organization  Manual  with  Saras  Mk  II included in the scope has been completed and list of Audit points received from the DGCA.
-  Fabrication of Tractor Configuration Nacelle components for Engine Test Bed nearing completion.
-  Inboards  model  version  11.2  in  progress  for  detailed  structural design/engineering.
-  Structural detail design of Airframe, outsourced to Private Company: Reports for detailed engineering design phase (D1) - Requirements capture phase finalized and D1-phase activity completed.
-  Fabrication  of  part  components  completed,  except  LH  Nacelle  for 1/6th scale wind tunnel powered model.
-  Saras PT1N taxi Trials BMS implementation - Phase 1 (proportional braking): modified open circuit/short circuit detection with Hardware in loop completed. Redesigned Artificial Feel Unit completed.

## Design,  Development  and  Certification  of  Hansa-Ng  (New  Generation Hansa Aircraft)

-  Structural test, flight test reports, design documents,  revised modification leaflets, compliance document, Airplane Flight Manual (AFM), etc were submitted to DGCA  for obtaining the final modification leaflet approval.
-  Aircraft Maintenance and Repair Manual (AMRM) has been prepared.
-  Received the final approval for all the following 13 major modification leaflets from DGCA
- o Design Modifications in Wing, Flap & Aileron
- o
- Design Modifications in Fuselage Assembly
- o
- o
- o
- Design Modifications in Horizontal Stabilizer & Elevator
- Design Modifications in Fin & Rudder
- Design Modifications in Main Landing Gear Design
- Powerplant Installation using Rotax 912 iSc 3 Sport Engine and MT
- o Propeller MTV-21-A-175-05
- o Installation of Fuel System for Rotax 912 iSc 3 Sport Engine
- o
- Implementation of Electro-Mechanical Flap Control System
- o
- Canopy Door Design Modification
- Modifications in Cowling, Fairings, Baggage Tray & Fire
- o Extinguisher Inst
- o Avionics System Installation
- o Electrical System
- o Aircraft Performance Characteristics with Rotax 912 iSc3 Sport Engine
-  Draft  Type  Certificate  Data  Sheet  has  been  prepared  and  sent  to DGCA.
-  RFP  issued  for  identification  of  production  partnership.  Technical bid under progress.

Technology Demonstrator - High Altitude Platform (HAP)

CSIR-NAL has also taken up the development of High Altitude Platforms

(HAP)  for  applications  like  broadband  communication,  surveillance, earth observation, climate research etc. High Altitude Platform (HAP) is a  solar  powered  unmanned  aircraft  envisaged  to  operate  at  the stratosphere  regime,  i.e.  approximately  20  km  altitude,  and  with maximum  endurance  so  that  it  can  emulate  a  perpetual  flight.  The subscale  model  aims  to  evaluate  the  Reynold  Number  effects,  flight mechanics,  stability  and  control  as  well  as  avionics  &  autopilot performance. The functional subscale model prototype was demonstrated at Wings India 2022. HAP will be a game-changer to work as a  pseudo satellite  for telecommunication applications in  the 5G & 6G  spectrum  with  advantages  like  low  data  latency,  high  bandwidth, the flexibility of launch and low cost.

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## Annexure-II

CSIR-NAL has developed medium class Beyond Visual Line of Sight (BVLOS) multi-copter Unmanned Aerial Vehicles (UAVs). The UAV is made out of light weight carbon fiber foldable structure for ease of transportation and has unique features like autonomous guidance through dual redundant micro-electro-mechanical system (MEMS) based digital Autopilot with advanced flight instrumentation  systems.  Directorate  General  of  Civil  Aviation (DGCA),  Ministry  of  Civil  Aviation,  Govt.  of  India  has  granted conditional permission to CSIR-NAL for conducting Beyond Visual Line of Sight (BVLOS) flight  trials  on 13 th   September,  2021. CSIRNAL's octa-copter can carry a payload loads upto 5.0 kg and 20.0 Kg  with  hovering  endurance  of  40  minutes.  It  can  fly  at  an operational  altitude  of  500  m  AGL  (Above  Ground  Level)  and  at maximum  flying  speed  of  36  kmph.  Its  regulatory  compliance includes Directorate General of Civil Aviation (DGCA)-No Permission-No Take (NPNT), Geo fencing and digital sky with 360 degree  Collison  avoidance  making  it  one  of  the  best  UAV  in  its class. The developed Quad-Copter is extensively used in acquiring Arial  Multi-Spectral  images  of  selected  medicinal  and  aromatic crops  covering  1,99,754  m2  area  maintained  by  CSIR-Institute  of Himalayan Bioresource Technology (CSIR-IHBT), Palampur.

The  developed  drones  by  CSIR-NAL  have  made  successful  field demonstrations  for  agri applications and  last-mile medicine  / vaccine delivery. CSIR-NAL's Oct-Copter UAV system that can carry a maximum payload of 20 kg and fly for the endurance of around 20 minutes has a provision to house either a hyperspectral camera for crop health  monitoring  or  a  fertilizer.  First  field  demonstration  of CSIR-NAL's Octacopter has been carried out for the farmers of Alur Agricultural  Produce  Market  Committees  (APMC),  Bengaluru.  In medical  application,  CSIR-NAL  has  teamed  with  Department  of Health & Family Welfare, Govt. of Karnataka for aerial delivery of covid-19 vaccine's in remote area. The Octacopter has successfully delivered  50  vials  of  Covid-19  vaccines  along  with  syringes  in  a

special container from Chandapura Primary Health Centre (PHC) to Haragadde PHC on 13 th  November 2021.

On  the  similar  lines,  CSIR-NAL  has  teamed  with  CSIR-Indian Institute of Integrative Medicine (CSIR-IIIM), Jammu and Department of Health & Family Welfare, Govt. of Jammu for aerial delivery of covid-19 vaccine's in remote border area. The Octacopter has successfully delivered 50 vials of Covid-19 vaccines along with syringes in a special container from CSIR-IIIM, Jammu  to  Sub-District  Hospital,  Marh,  Jammu  on  27 th   November 2021.

The developed multi-copter  technology has been  licensed to  four MSMEs for exploitation in agriculture and medical applications in the country.

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