Russia’s ambitious leap towards upgrading its Su-57 fighter jets with a ‘fifth-gen’ engine by 2024 comes amid production delays and operational challenges highlighted by its cautious use in the ongoing conflict in Ukraine.

This development, seen as an attempt to bolster its military capabilities, could provide the Su-57 with a significant boost in performance, potentially changing its role on the battlefield.

The state-owned TASS agency, citing two sources, announced that the new second-stage Izdelie-30, or AL-51F1, engine is now production-ready following extensive tests.

This upgrade, with its reported afterburner thrust of 18,000 kilograms, will allow the jet to supercruise over Mach 2, a capability that enhances both efficiency and stealth by eliminating the need for fuel-heavy afterburners, which increase heat signatures and potentially compromise stealth.

The aircraft’s lack of supercruise without an afterburner reportedly hampered its “stealth” and fifth-generation credentials.

The Izdelie-30, which has been in testing on the Su-57 since 2017, is positioned to replace the AL-41F1 engine also used on the Su-35. Moreover, the upcoming Su-75, Russia’s in-development fifth-generation aircraft, is expected to feature the Izdelie-30 when its maiden flight occurs in mid-2025.

However, Russia seems to have decided against retrofitting operational Su-57s with the new engine. Over ten Su-57s fitted with the first-stage Izdelie-30 have been deployed in Ukraine since 2023, with sources claiming that the current configuration surpasses the capabilities of the US F-35.

TASS quoted one of the sources: “There are no plans to replace the first-stage engines on the Su-57s already transferred to the Aerospace Forces with new engines.”

In addition to improved super-maneuverability and a better thrust-to-weight ratio, the first-stage engine boasts features such as “the oxygen-free plasma ignition system of the main and afterburner combustion chambers,” contributing to low visibility.

Despite these advancements, the Su-57 Felon remains somewhat of a rare sight in Ukraine, where it has been used cautiously, primarily for long-range strike missions with stand-off munitions.

These sanctions and production difficulties have impaired the country’s ability to mass-produce the Su-57 Felon, which is Russia’s most advanced fighter jet. Even the implementation of innovative augmented reality techniques in the aircraft’s assembly process has not overcome the challenges. Technicians use augmented reality to scan QR codes on major parts and receive instructions for assembly, akin to a high-tech version of IKEA furniture manuals.

Such processes are crucial for preserving the aircraft’s stealth attributes; even a minor misalignment caused by an improperly installed screw could impact its low-observable characteristics.

The Su-57 Felon carries an array of weaponry, including a variety of missiles and a 30mm cannon that, when not in use, is concealed to maintain its stealth profile.

Despite these capabilities and Russia’s efforts to field these advanced jets, production delays mean that many of the Su-57s in service are actually prototypes pressed into operational use.

Thus far, Moscow’s technological pride has failed to meet expectations and hasn’t made any difference in the largest conflict the Russian miliary has found itself since the Great Patriotic War in World War Two.

Relevant articles:
– Russia’s Su-57 to Feature ‘Fifth-Gen’ Engine in 2024, thedefensepost.com
– Russia’s Su-57 Felon Stealth Fighter Nightmare Just Won’t End, The National Interest