Global Defence Technology Insight Report

Introduction:

Steel demand in Aerospace & Defence Industry, despite the increasing use of advanced composites and lightweight alloys. Its demand persists due to its superior strength, durability, cost-efficiency, and adaptability to evolving military technologies. The technological integration of steel into various defence applications is driven by advancements in metallurgy, fabrication techniques, and mission-specific material engineering.

The Unsung Hero: Advanced Steels Driving Defence Innovation

One of the key technological trends boosting steel demand is the development of high-strength, low-alloy (HSLA) steels and maraging steels. These steels offer exceptional tensile strength, toughness, and resistance to cracking or fatigue under extreme stress, making them highly suitable for components exposed to high loads such as landing gears, armor plating, and engine mounts. HSLA steels also provide weight savings over traditional carbon steels without compromising on strength, which is critical for improving fuel efficiency and payload capacity in aircraft and naval vessels.

In military aircraft, steel is used extensively in structural components that require resistance to high-temperature environments, particularly in engine components and exhaust systems. Although titanium and composites dominate aircraft fuselage design, steel is preferred in areas where heat resistance and mechanical strength are paramount. In fighter jets, steel alloys are employed in afterburners, shafts, actuators, and arrestor hooks.

In the naval defence sector, steel plays an irreplaceable role in the construction of warships, submarines, and aircraft carriers. Special-grade naval steels, such as HY-80, HY-100, and HSLA-115, offer high yield strength and are used in submarine hulls and armored decks. These materials are engineered to withstand high-pressure underwater environments, ballistic impacts, and shock loads from torpedoes or mines. Additionally, corrosion-resistant stainless steels are used for piping, water systems, and other marine applications to extend vessel lifespan and reduce maintenance.

The New Era of Steel: From Advanced Armor to 3D Printed Components in Defence

In land-based military systems, such as main battle tanks, armored personnel carriers, and artillery systems, rolled homogeneous armor (RHA) steel and dual hardness steel (DHS) remain integral to protection solutions. These steels are engineered to absorb and disperse kinetic energy from armor-piercing projectiles. Technological improvements in welding, ballistic testing, and steel hardening processes have led to the development of modular and lighter armor solutions without compromising protection.

Furthermore, additive manufacturing (3D printing) is emerging as a transformative technology for the steel supply chain in defence. With the ability to fabricate complex steel components on demand, it reduces logistics burdens and enables field-level repair and customization. Powder metallurgy is being used to develop specialized steel powders optimized for printing high-performance parts in both aerospace and military ground systems.

Smart steel structures, embedded with sensors or integrated with stealth technology, are also being researched for next-generation military platforms. Steels magnetic properties are being studied for electromagnetic shielding and for use in railguns and electromagnetic launch systems aboard future naval vessels.

Conclusion:

In conclusion, while lightweight materials continue to grow in relevance, steel remains vital due to its unmatched combination of strength, durability, and cost-effectiveness. Ongoing innovations in steel alloys, forming techniques, and integration with emerging manufacturing technologies ensure that steel will continue to be a fundamental material across all domains of the aerospace and defence industry.