HAL Unveils CATS Warrior: A Significant Leap in Indian Aviation

HAL’s Latest Achievement: The Engine Ground Run

On January 11, 2024, Hindustan Aeronautics Limited (HAL) shared an image of the CATS Warrior. The announcement stated, “Successfully conducted the Engine Ground Run of a Full-Scale Demonstrator.” This milestone marks a critical step in the development of this advanced unmanned aerial vehicle (UAV).

Steps Before the Demonstrator’s First Flight

Before the CATS Warrior takes its maiden flight, several steps are essential. These include:

1. Engine Ground Runs: Engineers verify engine performance, fuel efficiency, and overall reliability.
2. Taxi Trials: The aircraft undergoes tests at various speeds to validate taxiing and braking systems.
3. Static Tests: Structural integrity is checked under simulated flight conditions.
4. Flight Readiness Review: Experts ensure all systems are functional and meet safety standards.
5. First Flight: The aircraft’s first airborne test evaluates real-world performance and maneuverability.

Each stage involves rigorous assessments, ensuring the aircraft’s readiness for operational deployment.

Specifications: Powering the CATS Warrior

The CATS Warrior’s specifications highlight its technological advancements. It is powered by two HAL PTAE-W turbojet engines. Here are the key features of these engines:

• PTAE-7 Design: A single-shaft, lightweight turbojet engine known for low cost and short life.
• Core Components: Includes a four-stage transonic axial compressor, single-stage turbine, annular flow combustion chamber, and 16 fuel flow burners.
• PTAE-W Enhancements: Features a new FADEC system and a time between overhaul (TBO) of 1,000 hours.
• Performance Metrics: Generates 380 kg.f of thrust with a specific fuel consumption of 1.15 kg/kg.f/hr.
• Physical Attributes: Measures 1.27 meters in length, 330 mm in diameter, and weighs 65 kg.

The combined engines deliver approximately 7 kN thrust, similar to the Kratos XQ-58 Valkyrie powered by the Williams FJ33 turbofan.

Comparing Power and Design

While the Kratos XQ-58 Valkyrie’s single Williams FJ33 turbofan provides slightly higher thrust, the PTAE-W turbojets make the CATS Warrior competitive. The Valkyrie’s engine, being a turbofan, offers higher efficiency and thrust. However, HAL’s dual-engine setup ensures redundancy and balanced power distribution.

Evolution of the Design

The initial concept design of the CATS Warrior differed significantly from the unveiled model. Earlier designs featured angular surfaces, prioritizing stealth. The refined version showcases smoother surfaces, which reduce drag but slightly compromise angular stealth. To compensate, the aircraft uses RAM (Radar Absorbent Material) coatings and laminations with over 99% attenuation. These advancements enhance performance while maintaining acceptable stealth levels.

Boundary Layer and Air Intake Design

One notable change is the redesigned air intake. The new intake better addresses the boundary layer—the layer of air close to the aircraft’s surface. Managing this layer reduces turbulence and ensures consistent airflow to the engines. Initially, HAL’s designs featured sharper angles. However, the refined concept, as shown in the transparent design image, incorporates smoother curves and improved intake geometry. These changes optimize engine efficiency and overall performance. This further helps “Warrior” to delivery valkyrie level payload with slightly less powerful dual engine configuration.

This at the moment is first prototype and design will get refined over the course of testing cycle and each further prototype or limited series production models will accommodate those changes. These changes could be addition or angular stealth or it may not be the case. However, at this moment nothing can be termed as fixed.

Overall, This technology represents a critical capability for the Indian Air Force, offering advanced unmanned aerial solutions to meet modern combat requirements. Once fully mature, the CATS Warrior will enhance force multiplication, enabling more effective surveillance, target acquisition, and precision strikes. Its integration will support missions requiring reduced pilot risk and provide strategic advantages in contested environments.