For most of the 20th Century, military advantage was purchased with money that only states could spend. Stealth coatings, satellite constellations, cryptographic systems, and precision-guided munitions were the products of defence budgets, classified laboratories, and export-controlled supply chains. That world is receding. A growing share of the technology that now decides battlefield outcomes—commercial drones, small satellites, foundation models, quantum computing, and advanced semiconductors—is developed first for civilian markets and only later adapted for war. The direction of technology transfer has quietly reversed, and with it, the advantage once enjoyed by states that could out-invest their rivals in military-specific research is eroding in ways that are difficult to see and harder to reverse.

This erosion is not dramatic. It does not resemble the loss of a battle or the collapse of a treaty. It shows up instead as a widening gap between what a nation’s defence establishment assumes it can do and what a determined adversary, or even a non-state actor with a credit card, can now do as well. Understanding which technologies are driving this shift, how the erosion actually happens, why it has accelerated now, and what a state such as India can do about it is the purpose of this paper.

The Technologies to Watch

Seven categories of dual-use technology deserve close and continuing attention:

• Drones and small unmanned systems. The same motors, cameras, radios, batteries, and flight electronics that power hobbyist drones now underpin tactical ISR platforms and loitering munitions. The crossover is strongest at the small end of the market, where mass-produced commercial components give attackers scale and cost advantages that were unimaginable a decade ago.
• Commercial space and satellite communications. Earth-observation constellations built for agriculture and insurance now provide targeting-grade imagery, while broadband constellations built for rural connectivity now carry military command traffic. A synthetic aperture radar satellite produces the same picture whether the customer is a farmer or an intelligence agency.
• Artificial intelligence and foundation models. Computer vision, autonomous navigation, and large language models developed for consumer and enterprise use now underpin drone targeting, signals analysis, and battlefield decision support. Much of this capability is openly published or commercially licensed rather than classified.
• Quantum computing. Still immature as a computing platform, quantum research already threatens the cryptographic backbone of secure military communications. Adversaries can capture encrypted traffic today and decrypt it once a cryptographically relevant quantum computer becomes available—a strategy known as harvest now, decrypt later.
• Advanced semiconductors. The chips that train frontier AI models and the chips that guide precision munitions increasingly come from the same fabrication lines, making export control an exercise in chasing a single, fungible commodity across a globalised supply chain.
• Cyber and offensive intrusion tools. Commercially sold spyware and intrusion frameworks, built and marketed as lawful-intercept or security-testing products, have repeatedly ended up enabling state-level surveillance and sabotage operations well outside their advertised use case.
• Additive manufacturing and precision electronics. Desktop and industrial 3D printers, combined with widely available design files, allow small workshops to produce drone airframes, munition components, and jigs that once required a dedicated defence-industrial supply chain.

How the Erosion Is Actually Happening

The mechanisms are quieter than they sound:

1. Cost democratisation. Platforms that once cost a state tens of millions of dollars to field now have functional civilian equivalents costing a few hundred or a few thousand. Ukraine alone is estimated to have produced close to two million first-person-view drones in 2024—a scale of precision-strike capability that would have been unthinkable for a state defence budget a generation ago, let alone for the non-state and irregular groups now copying the model.
2. Dependency substitution. Militaries increasingly rely on commercial infrastructure they do not own and cannot fully control. When Ukraine’s access to Starlink connectivity and Maxar’s commercial satellite imagery briefly became a point of political leverage in a negotiation over a critical-minerals deal in February 2025, it exposed how thoroughly modern militaries had come to depend on privately owned, foreign-controlled systems for functions once considered sovereign—communications and intelligence.
3. Silent obsolescence of cryptographic advantage. Encrypted government and military communications are already being harvested and stockpiled by adversaries who cannot yet read them but expect to within the next decade. Recent research has cut the estimated quantum resources needed to break RSA-2048 encryption from twenty million qubits to under one million, with credible estimates of a cryptographically relevant quantum computer arriving as early as 2029.
4. Diversion through globalised supply chains. Even where export controls exist on paper, enforcement struggles to keep pace with dual-use goods routed through intermediaries. In December 2025, the United States disrupted a network responsible for diverting more than 160 million dollars’ worth of advanced AI chips to restricted destinations—a single case among a steady stream of similar actions.

Why the Erosion Is Happening

The underlying causes are structural rather than accidental, and they will not resolve themselves:

• The centre of gravity for frontier innovation has moved from defence laboratories to commercial markets. Venture capital and consumer demand now fund research at a scale and speed that defence procurement cycles cannot match. A smartphone camera sensor, a drone flight controller, or a large language model reaches maturity in commercial markets years before an equivalent military-specific programme would clear its requirements process.
• The very nature of dual-use technology resists the tools states have traditionally used to control it. A rocket that launches a weather satellite can launch a reconnaissance satellite; a communications network built for rural broadband can carry military traffic; a robotic arm designed to service a satellite can just as easily interfere with one. Export control regimes built around discrete, identifiable military hardware struggle against technology whose military application is a matter of software configuration rather than physical design.
• Globalisation has distributed manufacturing and expertise across many jurisdictions with uneven enforcement capacity. Well-designed controls in one country can be routed around through a third-country intermediary, a shell subsidiary, or a permissive jurisdiction, as the steady cadence of diversion prosecutions illustrates.
• The states that own the largest share of dual-use infrastructure—commercial satellite operators, cloud providers, and chip manufacturers—are concentrated in a small number of countries. This means access to militarily relevant civilian technology is increasingly conditioned on the political relationship with the country hosting the provider, not merely on the buyer’s ability to pay.

What Can Be Done

None of this argues for retreating from commercial technology, which is neither possible nor desirable. It argues for a deliberate strategy that treats dual-use dependence as a risk to be actively managed rather than a convenience to be passively accepted:

• Build sovereign backup capacity. For functions where foreign commercial dependence has already proven coercible—satellite communications and imagery chief among them—states need at least a minimum viable indigenous or allied alternative that can be activated if commercial access is withdrawn or degraded.
• Accelerate the migration to post-quantum cryptography. Because harvest-now, decrypt-later attacks are already under way, waiting for a cryptographically relevant quantum computer to appear before upgrading encryption guarantees that today’s most sensitive traffic will eventually be exposed. Migration needs to begin now, prioritised by how long the underlying data must stay secret.
• Mandate secure-by-design standards for dual-use platforms. Requiring cybersecurity and anti-spoofing protections to be embedded at the design stage, rather than added afterward, for satellites, drones, and networked sensors closes a class of vulnerability that has already produced a documented rise in signal-spoofing incidents against space assets.
• Coordinate export controls with trusted partners rather than pursuing them unilaterally. Since dual-use goods move through globalised supply chains, controls that are not harmonised across allied jurisdictions simply redirect trade through the weakest link. Recent friction over unpredictable licensing has already strained cooperation between India and the United States on exactly this point.
• Invest in indigenous capacity in the technologies that matter most. Rather than attempting to control or replicate every dual-use technology, states should concentrate scarce capital and talent on sovereign capability in the handful of domains—secure communications, critical sensors, autonomous systems software—where dependence carries the highest strategic cost.
• Treat commercial-sector monitoring as a standing intelligence function. Because the technologies eroding military advantage are being developed in civilian laboratories and start-ups rather than defence establishments, tracking their maturation requires the same systematic attention traditionally reserved for tracking an adversary’s weapons programmes.

Conclusion The erosion of military advantage through dual-use technology is silent precisely because nothing about it looks like a threat when it happens. A start-up ships a better drone camera. A cloud provider trains a more capable model. A satellite operator signs a new broadband customer. Each transaction is commercially unremarkable. Only in aggregate, and usually only in hindsight, does the pattern become visible: capabilities once confined to defence budgets are now available to anyone with market access, and control over the underlying infrastructure has migrated from ministries of defence to corporate boardrooms in a handful of countries. For India, as for every state seeking to preserve a credible military edge, the task ahead is not to resist this shift—which is neither possible nor sensible—but to build the sovereign redundancy, cryptographic resilience, and coordinated export discipline that allow it to draw on the same civilian innovation without becoming hostage to it.

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Session 1: Inaugural Session

Maj Gen (Dr) Ashok Kumar, Director General CENJOWS, said that the deliverables are not fully visible in the Services as far as Surveillance & Electro Optics are concerned. Much more needs to be done. He further enumerated that the Surveillance & Electro Optics systems consist of one of the four components essential for warfighting and these are:

• Sensors -They are the eyes and ears that sense the situation in the air, land, and sea domain.
• Data and communication links through which sensor outputs are transmitted to the systems where it will be stored, analyzed, and acted upon.
• Command and Control Centre/ Data Fusion Centre, where the data will be processed and decisions are taken to respond.
• Shooter – is the final component which will react to the emerging situation.

The sensor is the most critical element of the loop, so surveillance using electro-optical sensors is the most important part of the chain. We need to investigate the spectrum and bandwidth the systems need to work upon efficiently. The systems must have the capacity to connect and work together with the three services, and the compatibility with the existing systems will improve their capabilities.

Lt Gen DS Rana, Director General Defence Intelligence Agency delivered the inaugural address stating that, electro-optical sensors harvest the capabilities of optics and electronics to analyze high-resolution visual images in real time. The current conflicts in Ukraine, the Red Sea situation, the South China Sea, the nuclear ambitions of Iran and firings by North Korea are driving the world into an unstable situation. In our neighbourhood, Pakistan is facing an economic crisis, and China, too, is increasing its footprints not only on land but at sea. The need for high-grade sensors onboard drones and space-based assets is proliferating. The role of commercial intelligence data by Maxar has helped Ukraine analyze the movement of Russian troops and counter the threat in time before the attack began. Ukraine has access to NATO-based intelligence, and Russia and Ukraine are continuously attacking the targets in depth using PNT. China has increased its space-based capabilities with EO imaging revisit of about fifteen minutes, two hours in SAR, near-continuous coverage of ELINT in the Indian region. It has ISR capabilities in geosynchronous orbit for round-the-clock coverage in the Pacific and Indian Oceans. China is developing a ground-based system in Pakistan that will enhance BeiDou accuracy to 15cm based on PNT to enhance its regional precision strike capabilities. The unmanned drones can conduct ISRs and are equipped with high-definition IR and SAR sensors. Pakistan is building up its capabilities for coverage of its land borders along Iran, India and Afghanistan using high-definition EO sensors fitted drones. HAPS are solar-powered drones that fly above 20 km for persistent capabilities for many months with a resolution of 15cm. Ground-based sensors can sense the movement of troops using acoustic sensors, and China has operationalized an EO grid along the Line of Actual Control for all weather coverage. The maritime role relies on various sensors, such as long-range patrol aircraft and acoustic sensors fitted on undersea autonomous vehicles. All these developments in the sensors onboard space, air and sea-based platforms have resulted in a paradigm shift in how intelligence is gathered. There is no shortage of data, and the use of data analytics and machine learning algorithms using AI will only help in analyzing the spatial data from a variety of sensors. The use of GIS for the fusion and visualization of spatial data is a growing field many intelligence agencies have adopted. The growth of MASINT (measurement and signature intelligence) is where data from multiple sensors capable of sensing data like electromagnetic, electro-optical, acoustic, and chemical composition are fused. Only the US and Israelis have this technology and our efforts to shore up this technology is the need of the hour. The next challenge is to fuse the data and generate the information using network nodes. These data can be shared in a secure grid to seamlessly counter emerging threats in various domains. He concluded by mentioning that the current global conflicts and geopolitical situations are driving the need for high-grade sensors onboard drones and space-based assets. Both China & Pakistan are developing space-based capabilities, including imaging and coverage in the Indian region. Further, the use of data analytics, machine learning algorithms, and GIS for spatial data fusion and visualization is becoming increasingly important. The growth of MASINT technology, which combines data from multiple sensors, is a priority for many intelligence agencies. The next challenge is to effectively fuse and share data to counter emerging threats.

The Keynote Address was delivered by Air Marshal Surat Singh, Director General Air Ops, Air HQ. He defined the emerging warfighting using the sensors in the following roles:

• Superior Battlefield transparency.
• Networking of all sensors.
• Shortening of OODA loop using automated data support loop.
• Swift response using agile weapons.

They are being done at the HQ level to enable the standardized operation of data formats, protocols, and interfaces. The aerospace domain requires the exploitation of space, air and surface-based sensors. The commercialization of space and dual-use technology must be used optimally. In addition, identifying threats in space, air surface and maritime has to be done almost on a real-time basis using private and public assets. The requirements for space-based solutions that the Air Force has met, are, Stratospheric and persistent platforms assets, Low-cost and fast deployable and expendable assets, Interface with the existing networks like the IACCS system. It enhances the space segment and sensors’ networking to provide sufficient early warning and intercept opportunities. He concluded by discussing the use of sensors in emerging warfighting strategies. These must be implemented for achieving superior battlefield transparency, shortening the OODA loop, integrating all sensors, through automated data support. The air and space domain requires the optimal use of space, air, and surface-based sensors, commercialization of space and dual-use technology. Real-time threat identification in various domains is crucial and can be achieved using both private and public assets. He concluded that the Air Force has successfully met the requirements for space-based solutions, including stratospheric and persistent platforms, low-cost and fast deployable assets, and interface with existing networks.

A Special Address was delivered by Dr BK Das, DG Electronics and Communication Systems (ECS), DRDO. He highlighted that DRDO was working on a comprehensive approach to monitoring warfare trends, both in the outer space and undersea domains. It will be a non-contact war with autonomous weapons with robotics and cyber playing an important role. The next engagement is characterized as zero physical touch, as it will involve use of autonomous weaponry, AI based robots and cyber warfare. Technology wars would require careful re-alignment between country’s tech capabilities, weapon manufacturing, and industrial infrastructure to sustain them. Prioritizing development and maintenance of technological edge is crucial to come out of reliance on the other countries. DRDO is deliberating various options for services, to include SAR and LIDAR technology, advanced radar technologies, and the concept of a “Digital Soldier as a System.” The Services will utilize AI-based electro-optic soldier, autonomous decision-making abilities, robotics capabilities, and its ability to network. Cognitive Warfare is using advanced technologies to disrupt or manipulate adversary’s cognitive processes, while first-person drones will be resistant to EI & RF Interference. He further spoke about how Quantum computing will be used for surveillance in multi-domain battlefields which will facilitate object detection and identification through data gathering, fusion, and analysis. In conclusion, he re-iterated that the DRDO is working towards a comprehensive approach to monitoring warfare, incorporating technologies like artificial intelligence, space warfare capabilities, nanotechnology, big data, and additive manufacturing.

Col K V Kuber, Director Defence & Aerospace, Ernst & Young gave the industry perspective. He said that interoperability was the key for a functional surveillance system with impunity. Indian industries must collaborate with global vendors to get competitive. To reduce Indian dependence on foreign countries, we have to pep up our industrial base and ecosystem. Investment in the indigenous industry is essential to reduce India’s reliance on resources of the other countries. Strategic partnerships are the key. AI will be applied in almost all domains for crucial inputs on data. Sensors in all domains will be used to boost situational awareness and manage information overload. He concluded by re-iterating that data is crucial for intuitive design and industry must develop advance technology in sensors globally. We must ensure that India should be fully prepared indigenously for potential confrontations and early use of weapon systems based on sensors in all domains.

Session 2: Terrestrial Surveillance

The session was chaired by Brig Anurag Asthana, Brig Ops, Artillery Directorate, Army HQ. He introduced the session by drawing inferences from present global scenarios and how countries are striving for military development. He referred to the 7 October 2023 attack launched by Hamas on Israel as an example of growing conventional and asymmetric warfare equipped with lethal weapons. Touching on the session theme ‘Terrestrial Surveillance’, he reiterated the significance of multi-sensors and how the Indian Army was continuously working to upgrade surveillance facilities. He said that future battlefields would be driven by miniaturized Unmanned Autonomous Systems (UAS) and Artificial Intelligence (AI), highlighting how AI was being used for reading huge data and had opened “new vistas.” He flagged the requirement of surveillance through deployment of sensors that would allow sufficient time to process data. Passive surveillance would remain beneficial than active surveillance and that the surveillance grid needs to have full proof communication systems.

Shri Madhukar DIG (Ops) Force HQ BSF covered the challenges being faced by the Border Security Force in managing the borders at night. His presentation showcased an overview of the responsibilities of the BSF, present facilities related to surveillance and future challenges that requires to be addressed. Stressing on the dynamic terrain and climate of the Indian subcontinent, the speaker elucidated on the peace time and wartime responsibilities undertaken by the BSF for each of the geographical commands. The Western Sector revolves around the increased use of UAVs, tunnelling across international borders, low visibility during winters, poorly lit areas and non- effectiveness of Surveillance equipment during winters. Similarly, the challenges in the Eastern Sector are specific to altitude and temperature. The BSF has incubated several responses that include Hot Interception Team, Naka cum Ambush, Foot patrolling, Anti-drone operations and even Boat Naka. He further highlighted several projects undertaken by the BSF and comprise of ‘Comprehensive Integrated Border Management Systems’ (CIBMS), ‘Electronic Surveillance of vulnerable patches’ (ESVP) and OCTS project. In the concluding remarks he reiterated continued collaborative measures between BSF with DRDO, IITs and agencies like NTRO for technical solutions with integrated security system at borders. Additionally, the introduction of smart fences will be a game changer with high tech surveillance devices such as sensors, ground-based radar systems, etc, to provide a holistic surveillance mechanism.

Col Sameer Babu, Colonel (C&R), Army AD Directorate, Army HQ, spoke on the Latest Developments in Tackling Threats and C&R for Air Defence, emphasized that Army AD was the largest user of radars amongst the three Services. He touched upon the threats emanating from various altitudes and speeds which call for a dynamic surveillance system in addition to the existing ones. He also highlighted the evolving air threat and the growing impact of air power with the need for an effective air defence capability for land operations. Advancements in radar technology was flagged. Development of passive radar technology will remain a game changer since it is highly cost-effective and compliments existing radar systems. Multiple Inputs, Multiple Output (MIMO) radar technology that has evolved from communications systems provides an edge by simultaneously radiating uncorrelated signals, improving coverage and signal quality. He also flagged the use of ‘Digital Beam’ technology that can be deployed to achieve higher angular resolution and wide coverage without mechanical moving parts. The usage of ‘Active Electronically Steered Array Radar’ and ‘Radar Digital Signal Processing’ were also discussed.

The session also saw participation by several industry players and start-ups who making strides in surveillance and electro-optics equipment.

Vaibhav Gupta, Director, MKU Ltd, spoke on Electro-Optics: Shaping Modern Warfare & Defense Strategies – Learnings, Lessons & Implication In 2024. He spoke on how electro-optics was shaping warfare and defence strategies by drawing lessons from contemporary conflicts, which revealed larger and recurring requirement of equipment and night vision devices, enhanced role of sensor-based technologies, and the need for efficient solutions which deliver “first salvo effectiveness.” This meant there was a need to be self sufficient in manufacturing and core technologies. He then presented MKU’s Smart Soldier Solutions (Netro Soldier Optronics and Kavro Soldier Protection) and Smart Platform Solutions (Netro Platform Optronics and Kavro Platform Protection).He also gave details of MKU’s facilities and reach of its products and clients around the world.

Ram Biron, Director of Marketing, SCD, Israel, spoke on Advanced integrated applications utilizing high definition format IR detectors. He gave details about SCD’s credentials, facilities, core technologies in infrared detectors and video engines. He explained SCD’s share of cooled 2nd-gen scanning and staring FPAs, InGaAs FPAs detectors and modules in the defence market. He covered key global trends in IR sensors which were driving SCD’s road map. His presentation included SCD’s cooled detectors and video engines (MW/LW), new-gen SWIR solutions, combined HD MWIR and 3rd-gen ALPD SWIR, and next-gen DAS for armoured fighting vehicles.

Sandeep Shah, Managing Director, Optimized Electrotech, spoke on Assisted & Automated Surveillance. He gave details about the company and progress, patents, certifications, and clients. He cited challenges in surveillance – border conflicts, undemarcated borders, infiltration, and specific geopolitical and geographical challenges in India. He gave details about Optimized Electrotech products – NoctVision, InfiVision, ClearVision, and OmniVision. He also gave details and benefits of Autonomous AI based multi-spectral surveillance platforms.

Abhinav Gupta, Managing Director, SES, spoke on Rechargeable Li-Ion Batteries for Military Devices. He gave an overview of his company, products, present challenges in battery use, indigenous solutions, capabilities and in-house facilities. SES has worked for Indian and Israeli armed forces. SES solutions included smart chips and intelligent programming, intelligent electronics, advanced machining, novel materials and innovations.

Vinod Yadav, Head-Technical (Optronics & Computing Platforms), Tata Advanced Systems Ltd spoke on Products and Solutions in Electro-optics. He gave details about Tata Advanced Systems’ business verticals, product portfolio (Weapons, Sensors, C4I systems), and particularly the portfolio in electro-optics (cooled TI systems, uncooled TI systems, II-tube based NVDs). He gave details about short-range observation systems, long range observation systems (Rajak ULR), modular long range surveillance platforms, weapons sights, crew vision systems. He also spelt out TASL’s future technology focus areas.

Ramkrishna Siddam, General Manager, Optica spoke on Complete Solutions for Next-Generation Electro-Optical Systems. He overview of his company, capabilities, certifications, products, core expertise, testing facilities, and optics & electro-optical systems including Schlieren Systems, optics for TMT, Aerosol LIDAR, Cloud LIDAR, MIR LIDAR, FTIR System, Adoptive Optics BDOC System, Light Weight High Power Laser Mirror, IR panoramic camera and ongoing projects including Surya Tilak project for Ram Mandir at Ayodhya.

Session 3: Aerial In Space-based Surveillance

The session was chaired by AVM Rajiva Ranjan, ACAS Ops (Space), Air HQ. He said that military intelligence was the key to war. Space and air are the ultimate frontiers. In 1991, Space ISR became prominent. Aerial and SAR systems are very vital assets for military in multi-domain operations. Aerial SAR, integrated on aircraft, offers various advantage of fast deployment and flexibility, enabling real-time monitoring and target identification in various terrain and all domains. These systems provide crucial intelligence for mission planning, threat assessment, and battlefield situational awareness. On the other hand, SAR satellites provide persistent surveillance capabilities to monitor vast areas continuously for global coverage. They offer high-resolution capabilities that detect and track moving targets and assess changes in the environment. Both aerial and space-based SAR systems were integral components of military reconnaissance in providing invaluable support for operations, intelligence and decision-making processes in all domain.

Col Jasbir Mann, Col Aviation-10, Army Aviation Directorate spoke on UAV sensor payloads for persistent surveillance, and emphazied on the technologies for future warfare which could include three main types of technologies – Foundational, Strategic and Tactical. Examples included Artificial Intelligence, space technology and cyberwarfare. There is also a list of other advanced technologies like nanotechnology and robotics. He mentioning the need of all-weather aircraft and surveillance systems with capability of contemporary payload with high resolution.

Wg Cdr Aruna Singh, DIPAC, Def Space Agency spoke on Space-based ISR for early warning. Space Surveillance along with Military operations rely heavily on surveillance and reconnaissance, to perform strategic and tactical imaging over areas of interest with persistent surveillance. Geosynchronous satellites offer wider surveillance over wide areas particularly denied by other surveillance devices. The speaker highlighted the significance of gathering intelligence to effectively plan and carry out military operations, making well- informed decisions. She discussed the importance of adjusting military forces in response to shifts in an adversary’s order of battle (ORBAT) and making necessary revisions to future actions. Regarding EW satellites, she mentioned that they are designed to specifically detect ballistic missile launches. It was later incorporated into missile defence systems and regulatory control systems for nuclear tests as these satellites have the capability to detect a missile launch right from the start of its trajectory. They utilize infrared sensors to detect missile engines based on the intense heat emitted by their flames. They possess a distinct advantage over radar in their ability to scan a significantly larger area. As on date, three nations-USA, Russia, and China possess constellations of these early warning satellites. Lastly, she emphasized the advantages of the Space-Based Infrared System (SBIRS). This system consists of a network of satellites in geosynchronous Earth orbit and payloads in highly elliptical orbit, all managed by ground processing and control systems. These systems are held by three countries only so far.

Air Cmde Hrushikesh J Page, Air Cmde Int (Ops), Air HQ spoke on Latest developments and requirements for Tactical Recce (EO, SAR, IR Search). Having a deep understanding of tactical reconnaissance is crucial for successful military operations. It allows for thorough analysis of the ever-changing dynamics of the battlefield, accurate identification and prioritization of targets, efficient management of information dissemination, and effective communication. It is of utmost importance in dangerous environments such as nuclear, biological, and chemical. The equipment needs to possess a high level of agility, resilience, efficiency, and seamless integration with systems. Utilizing cutting-edge technology, such as face and text recognition, is crucial for precise identification. Security and compatibility are of utmost importance. Having equipment such as ELINT, SAR, and IR is crucial.

Dr Manvendra Singh, Scientist G, IRDE, DRDO spoke on Intelligence Gathering with EO Sensors for Today’s Missions.

Session 4: Maritime Surveillance, Research & Development

The session was chaired by Cmde Ashish Bhargava, Cmde Air Warfare & Flight Safety, Naval HQ. He emphasized the importance of maritime surveillance in the Indian context owing to the long coastline. He said that maritime surveillance was an amalgamation of a lot of platforms with sensors with the inherent challenge of transporting the data due to absence of terrestrial network.

Comdt Banshidhar Singh, Joint Dir Communications, Indian Coast Guard spoke on Surveillance against Aerial, Surface and Underwater Threats. He highlighted the importance of surveillance in the maritime domain for ensuring an appropriate response to any developing situation relating to maritime safety and security. He defined the objectives of maritime surveillance to holistically understand, anticipate and administer all events and actions related to the maritime domain that could impact the maritime security. He said that it includes and relies on maritime law enforcement, maritime pollution and marine environment control, disaster response, search and rescue, anti-poaching, anti- smuggling, anti-human trafficking and safeguarding countries’ trade and economic interests. So, the prime objective is to detect any suspicious or anomalous target that could subvert the national interest in the maritime zones. He acknowledged the need to upgrade capabilities by keeping in tune with the advancements in technologies and put forth some recommendations for the ICG which include adaptation of existing magnetron-based radars to solid-state radars, daylight CCD thermal imager with laser illumination, electro-optic system to HD thermal camera, CCD with short wave infrared technology to see through haze, fog, glass, and better ranges, and inclusion of satellite AIS for better coverage.

Cdr K Varun, Cdr AW, Naval HQ spoke on Integrating Assets for Maritime Surveillance. He talked about complexity of maritime surveillance of the IOR because of the amount of maritime traffic that transits this region which is further exacerbated by the thousands of fishing boats and the requirement of keeping an eye on the three domains of surface, sub-surface and air by the Indian Navy. He also mentioned the government’s stance on India being the ‘First Responder & Preferred Security Partner’ and the role being played by the Indian Navy currently in the Gulf of Aden. He spotlighted the importance of Maritime Domain Awareness (MDA) and its centrality to the information, decision and action cycle. He mentioned the various fixed & rotary wing and manned & unmanned platforms and the surveillance sensors in service with IN for building the MDA. He also covered the various surface and sub- surface platforms, sensors and weapons utilized by the IN towards the task. He threw some light on how all this data from the IN’s sensors and from other agencies including space is aggregated, correlated and disseminated by the Information Management and Analysis Centre (IMAC).

Maj Gen (Dr) Ashok Kumar, Director General CENJOWS gave the closing remarks, alluding to the rise of India as a leading economic power and the need for the defence forces to rise to the challenges towards which the three services are willing to state their needs in an open and upfront manner and there is much visible collaboration between the forces and the industry. He said that the defence forces are ready to hand-hold those who are willing to be partners in the growth of the defence forces and the nation.

Maj Gen Ravi Arora, Chief Editor, Indian Military Review, ended the seminar with a vote of thanks to the speakers, subject matter experts, sponsors, exhibitors, all attendees and CENJOWS for the success of the event.

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SESSION 1: INAUGURAL SESSION

Opening Remarks. Lt Gen Sunil Srivastava, Director CENJOWS, emphasized on the importance of critical and advanced materials and its supply chain across the continents and how the recent conflicts in Europe and Middle East had affected the availability of special materials. He highlighted importance of advanced materials in weapon platforms to achieve the asymmetric advantage over our adversaries. Nano-materials, meta-materials, multifunction materials, and biomimetic materials are all smart materials which are being leveraged to have supremacy in the battlefield. Countries like United States, Australia, France, Germany, Japan, have got critical material strategies and policies. We are still yet to announce a critical materials strategy or policy.

Our country spent close to $2 billion worth of imports of advanced materials every year and majority of this comes from a potential adversary which is an issue of great concern. We have indigenized most of our systems but the special materials for these systems are being imported. We need to be conscious as to how we get self-reliant for semiconductors and critical material. The Mineral Policy of 2020, has already assured a lot of corrective policy measures. The Mines and Minerals Development and Regulations (MMDR) Act of 1957, has been amended twice recently as a result 30 critical minerals have been identified and opened up for auction to the private sector. Even Lithium has now been deregulated. For global partnerships, India is now engaged with the outside world through Initiative on Critical and Emerging Technologies (ICET) with the United States. India has also signed the Mineral Security Partnership in 2023, with the US and 12 other entities including EU. India has also inked a Critical Mineral Investment Partnership with Australia. It has signed MOUs to engage with Chile, Argentina, Australia on getting Lithium, Cobalt and other special metals and to translate this into action, all the stakeholders were expected to brainstorm the issues.

Keynote Address. Dr Samir V Kamat, Secretary Dept of Defence R&D & Chairman DRDO, emphasized that to have significant improvement in the performance of the defence systems, better materials with superior manufacturing technologies were required to be put in place. Unfortunately, we have not paid much attention to this important field. If we want to achieve our prime minister’s dream of Atmanirbhar Bharat and technology leadership in this Amrit Kaal, we have to pay greater attention to this stream of technology.

Broadly, materials can be divided into structural and functional materials, based on their roles. There are materials which perform the load bearing task for any weapon platform and there are materials which perform certain functional role of specific nature. Structural materials are materials such as steels, aluminum alloys, titanium alloys, polymer matrix composites, ceramic matrix composites. Functional materials are semiconductors, silicon, gallium arsenide, gallium nitride, permanent magnets and stealth materials.

We have been fairly strong in the structural materials. However, manufacturing of functional materials remains a grey area for us. We were left behind in the Silicon race in the 70s. For the new semiconductor materials developed for high power electronics such as silicon carbide, we have to ensure that we do not miss the opportunity. If we want to design hypersonic missiles, we need to first develop the scramjet propulsion and to develop scramjet propulsion, we need to develop materials which can withstand those high temperatures. To achieve that we need to look at niobium alloys, and nickel based super alloys with cooling channels.

Developing materials for defence and aerospace has several challenges. Some of these challenges are low volume and sporadic orders for the industries, stringent requirements for qualification and certification exponentially increasing the overall cost. However, the most significant challenge is the long development cycle for any material development. The design cycles for new weapon systems are shrinking. They are now down to about 4 to 5 years where as the new material development cycle is 10 to 15 years. So it is extremely challenging for a designer to starts designing a system to decide which material he should use. Lots of attempts internationally are now being made to see how this new material development cycle can be shrunk. Efforts are being made and over the next 10-15 years, we will be able to make some progress in lot of fields. The other initiative which is happening globally is known as the materials genome initiative which is a more hybrid approach.

It is the materials modelling approach including rapid experimentation approach and also using artificial intelligence and machine learning approach. Lot of material data has been collected over the years and using AI-ML tools. It is possible to get some insight into what should be a material or what should be the composition of a material or what processing should be used to achieve the desired outcome. As a nation we must have a more collaborative approach where academia, R&D institutions as well as industry work together to achieve this goal. The challenges start when we have to scale up from laboratory to industrial scale. The challenges are not only technical in nature but also techno commercial because unless the volumes are large, the cost becomes high. The issue of the infrastructure required for materials manufacturing is also very costly. 

Theme Address. Lt. Gen Manjinder Singh, DCIDS (PP&FD), HQ IDS highlighted the overwhelming reliance on China for critical hardware and special materials. The inclusion of fabrication and production of semiconductors through the new semiconductor policy was a welcome step. Dwelling upon the broad application of 3D printing, additive manufacturing from its initial beginning on a commercial scale, it has come a long way from medical equipment to space. The recalled Deng Xiaoping’s remarks about crude oil being synonyms with the Gulf and rare earth elements to China. ICT industry was seeking safer sources for conductors and semiconductors outside China. This is where India stands to gain. The West’s over-independence on China for rare earth elements has exposed the critical fault lines that are now being addressed globally. Tech giants like Apple, Boeing, Lockheed Martin are tightly coupled with China on the relevance of advanced materials, semiconductors and rare earth elements and trying to decouple the same. India must move into the semiconductor space with attractive investments opportunities to create a credible alternative to China’s manufacturing industries. Tata Group’s acquisition of the Bristol plant for manufacturing chips and iPhones in India demonstrates India’s intent to harness the opportunity of decoupling from China.

Modern war demands fighting and winning with indigenous solutions. Adoption through innovation of critical emerging technologies such as advanced materials, rare earth elements, composites and semiconductors are the way forward for our nation and to achieve this public, private sector industries, academia, and defence forces needs to collaborate frequently at all echelons. The government is putting policy and procurement measures in place, requisite hand-holding of industry, exploring this space is need of the hour for capability building and obviating foreign dependencies in this field.

Special Address. Maj Gen Charanjit Singh Mann, Additional DG Army Design Bureau highlighted the perspective of a user. He mentioned that the quality, type and composition of materials is insignificant for the user. What matters to the soldier is that it should be able to perform the desired task. He highlighted the kinds of advanced materials which are required for land forces applications. He mentioned about the importance of higher strength to weight ratio because it leads to overall weight reduction for the soldier’s equipment and weapons. He also emphasized upon high thermal stability, enhanced electrical conductivity, strength performance, higher sensing capabilities, and energy storage along with, durability factors of the equipment which impacts its overall configuration for fighting a battle. Speaking about each of these parameters he mentioned that land systems should be lightweight, flexible with higher performance to improve the agility for a soldier and afford manoeuvrability to the platform. All efforts should be made to reduce the overall load of a soldier. Even two kgs of helmet is also heavy for him during combat. Similarly, the bullet proof jackets or vests should also be as light and flexible and protective in nature. The materials used in unmanned aerial systems, directed energy weapons like Laser, Microwave systems should be able to withstand high temperatures. Special batteries, which are lightweight and compact are required. Conformal sensors and integrated circuits should be small and light with improved aerodynamic.

The communication systems have to be lightweight high performance antennas. EMI shielding should also have high signal integrity and low loss. Similarly, counter measures systems should also light weight high portability with ability to detect stealthy assets. For example, radar systems equipped with advanced signal processing algorithms and integrated with meta-material based antennas should be able to dissipate the effectiveness of strength materials by unique electromagnetic properties. The requirement of keeping the troops warm at high altitude regions should use materials which can withstand the wear and tear of weather and extreme fluctuation of temperature. With advanced materials we can achieve a much more efficient habitat system. He highlighted certain initiatives, projects which are under consideration, eg, protective spray on coatings and paints, especially for the unmanned aerial systems protecting them from high power laser weapons, the nano caffeine absorber coatings for different kinds of defence applications ceramic protection solution for armor protection, low cost sensor technology to detect different bio-warfare agents, smart thickening, fluid-based, ultra-resilient, adaptive kinematic soft rubber armour, sub-zero temperature Lithium-Ion batteries for supporting high altitude operations, energy harvester assisted power bank for mobile equipment, which shows a comprehensive integration of advanced materials across diverse domains within the defence forces.

Col Kuber highlighted that China had imposed export restrictions on gallium, gallium and germanium in response to American sanctions exposing the vulnerabilities of Western countries on dependence on China for critical raw materials. Turkey does not have certifications, which is time consuming and sometimes frustrating. They follow the supply and demand concept along with user requirements and they are one of the largest exporters of special materials. As far as China’s ambitious Belt Road initiative is concerned, they are proactively engaged with African Union countries and Australia to meet their burgeoning demand. China is diversifying its supply sources by investing in Africa and Australia. India has placed certain materials in the positive list of indigenization, which is highly significant for the industry. Raw materials which are available in India, should be banned for import. Government of India policy on critical minerals declared in June 2023 enables the private players to explore and mine these minerals. This is a defining moment for the industry.

SESSION 2 : ADVANCE MATERIALS FOR AEROSPACE

Session 2 was chaired by Air Vice Marshal Yalla Umesh, Asst Chief of Air Staff (Engineering), Air HQ.

Prof Ravi Shankar Kottada, Dept of Metallurgical & Materials Engineering, IIT-Madras, spoke on Stealth Materials, Components and Technologies for Aero applications. He explained the latest technologies in preparation of special advanced materials. He highlighted that Addictive Manufacturing was the process of joining materials to make parts from 3D model data. Elaborating on these methods he explained the process of Metal Additive Manufacturing (AM) by Laser Powder Bed Fusion (PBF), Direct Energy Deposition (DED), and Sheet Metal Lamination method. Chessboard Strategy results in better properties in alloys.

Srinath Ravichandran, CEO Agnikul Cosmos, covered the essential aspects of Agnibaan, which is an Agnikul’s mini space launch vehicle. The vehicle is dedicated and fully customizable for launching small satellites. It offers a 40 times faster launch turnaround which is a significant improvement in launch scheduling. The vehicle is linearly scalable from carrying 30 kg to 300 kg, indicating cost-effectiveness for various payload sizes which is 10 times cheaper. The Visitors att engines are named Agnite and Agnilet. Each Agnite engine can produce 25kN of thrust at sea level and can be configured with 4, 5, 6, or 7 engines. The Agnilet engine produces 8kN at vacuum. Its first flight was scheduled for Nov or Dec 2023.

Alok Singh Chauhan, Scientist F, DMRL, DRDO, spoke on Superalloy Casting Technologies For Aero Gas Turbine Engine Applications. He included:

• 3D printing as Manufacturing Technique in Aerospace.
• Application of Copper in Aerospace.
• Engine Components.
• Landing Gear Components.
• Electrical Wiring and Connectors.

Covering the canvas of Challenges in 3D printing of Copper & Smart alloys, he brought out issues pertaining to :

• High Thermal Conductivity.
• Oxidation Sensitivity.
• Printability.
• Thermal Stresses and Cracking.

The chairperson concluded by highlighting that all super alloys may not be meant for manufacturing. While super alloys are highly specialized materials known for their exceptional mechanical strength, resistance to thermal creep deformation, good surface stability, and resistance to corrosion or oxidation, they might not always be suitable for use in manufacturing processes.

SESSION: 3 – ADVANCED MATERIALS FOR LAND SYSTEMS, MISSILES AND NAVAL APPLICATIONS

The session was chaired by Rear Adm K Srinivas, Asst Chief of Materials (Dockyard and Refit), Naval HQ. He opened the session by highlighting importance of advance materials in manufacturing of battle ships for the Indian Navy. The Indian Navy uses specific material for ship building, eg, advanced steels for hulls for ships. Materials used for hulls is completely indigenous, highlighting Atamnirbhar Bharat success story. These materials are being developed by DRDO through integral research fraternity. Composite materials used in ship-building to reduce weight and increase stealth features are constantly being improved locally. To highlight self sufficiency of the country in the field and specialisation, it was mentioned that Vizag Dockyard uses 22 different types of steels for various manufacturing activities. Indian Navy’s requirements in future will be met completely through indigenous sources. Research & development by DRDO on fuel cells, coatings, thermal conductors, alloys, etc was also highlighted.

Cdr BK Singh from Directorate of Naval Design, Naval HQ, spoke on Special Materials for Ships and Submarines Building.” He gave information about structural materials used for ships/submarines and the types of materials used – high strength low alloy steels for hulls, Titanium and Cu-Ni alloys for pipes, Aluminum alloys for superstructures, composites materials for hull of small crafts, and cladded steel for interface structure. Covering the canvas of material failure he mentioned that it primarily occurred in the form of fracture/ fatigue/ creep. He emphasised upon the desired strength of materials required and explained factors of yield strength, resistance to brittle fracture, toughened materials and good ability to get welded. He mentioned that constant efforts were being made to develop high strength steel. He spoke about challenges faced in Titanium welding and future development of materials with improved qualities like steels with yield strength of 1000 MPa, metal fiber composites and biometric hull.

Lt Col Kunal Tagunde, Instructor Call A, College of Military Engineering, Pune spoke on Latest Developments in Impact Absorbing Body Armour. He gave the historical perspective, mismatch in requirements versus products in use by troops. He highlighted the aspects of flexibility, ergonomics, latest trends, new and innovative materials being developed, eg, Fiber, CT, Carbon Nano, etc. He briefly covered the Initiatives By CME, Pune on project Padam Kawach.

SESSION 4 : SMART & FUTURE MATERIALS/REAR EARTHS & SEMICONDUCTORS

The session was chaired by Rear Admiral (Prof) Deepak Bansal, IIT-Madras. He highlighted the need to devise a strategy to develop an ecosystem related to chips as well as special materials by bringing together all stakeholders including the Govt. He mentioned that Rare Earths are in abundance, however, these oxidised materials are rare because most deposits are of low in concentration and takes lot of efforts to process them.

Anuttam Mishra, Director (Technical), Indian Rare Earths Ltd spoke on Smart and Future Materials and Rare Earths. He recounted efforts of DAE in last 40 years. He said that rare earths were a group of 17 chemical elements which were used to produce useful high-tech products. Seven minerals are available in India which are processed by Rare Earths. Out of these thermal applications materials have been provided to Defence and BARC. Though the Rare Earths have offered finished material like phosphorous catalyst, etc, to the civil industry for exploitation, it has not found much success. There are few mining sites with limited mining capability, hazardous residue, long gestation period, highly capital intensive, due to economy of scale and low consumption. Most materials are highly radioactive and, hence, need high order of safety measures in their handling.

Dr Kingsuk Mukhopadhyay, Scientist G, DMSRD, DRDO spoke on Smart polymer, fibre & fabrics for stealth, extreme cold, fire resistant & ballistic protection. One of the major challenges for portable water filtration is rate of filtration due to insufficient gravitational pressure. A mitigation technology in compact area is developed by DMSRDE using porous nano fibres which don’t use any chemical or electrical power for purification.

DMSRDE has prepared unique SSG which shows the change in viscosity as a function of shear force and holds a great promise for damping and shock energy dissipation. Besides this DMSRDE has successfully developed modular Bullet Proof Jackets (BPJs) to provide 360-degree protection as per the laid down GSQR.

Functional Materials for Radar Absorbers are Dielectric materials which impart dielectric polarization losses whereas Magnetic materials Imparts magnetic losses Ferrites, carbonyl iron, iron silicide. He also informed the audience about the development of Camouflage Systems, Synthetic Camouflage Net for Snow Bound Area (SBA) & green belt area produced and supplied to army. Radar Absorbing Camouflage Net (RSCN) were found effective against Visual, IR and Radar Surveillance. Multi-Spectral Camouflage Net (MSCN) effective in Visual, NIR, TIR and MW bands, Multispectral Personnel Camouflage Equipment and Mobile Camouflage System (MCS) have been developed.

DMSRDE successfully developed Boot Anti Mine Infantry (BAMI) for Infantry troops Indian Army and CAPFs.

Other equipment developed by DMSRDE includes NBC Suit Permeable, NBC Gloves, Advanced Chemical Protective Gloves, CBRN Overboot, NBC Facelet Mask.

Dr Apurba Sinhamahapatra, from CSIR-CIMFR, Dhanbad extensively covered Shaped Memory Alloys as the smartest materials, known for their unique ability to recover their original shape after undergoing deformation making them useful for precise and reversible shape changes. The alloy called Nitinol named after Nickel-Titanium Naval Ordinance Laboratory, displayed the ability to return to a predetermined shape after being deformed when exposed to heat. It has found greater applications in the medical devices, including vascular stents, guide wires, and orthodontic devices. Currently, its applications have gone beyond medical to include aerospace, robotics.

He also gave details on types of Shaped Alloys – One Way alloy which remembers only one shape. The other remembers two different shapes, one at a lower temperature and other at a higher temperature. Iron and copper based SMAs such as Fe-Mn-Si and Cu-Zn-Al are commercially available and cheaper than NiTi. High strength and lightweight material like Nitinol is known for its high strength-to-weight ratio, making it suitable for various engineering applications.

KNS Pavan Kumar, Scientist B, YSL-Smart Materials, DRDO covered the topic of Applications of Smart Materials for Future Military Electronics Applications. He spoke about

• Actuators and Adaptive Structures
• Deployable Structures
• Aircraft Components
• Space Mechanisms
• Satellite Components
• Aircraft Engine Components
• Self-Repairing Textiles
• Enhanced Load-Bearing Equipment
• Adaptive Camouflage Cloaks
• Biomechanical Support Systems
• Adaptive Control
• Morphing Wings of Aircraft
• Deployable Structures
• Temperature -Responsive Uniforms
• Bulletproof Vests with Shape Memory Properties
• Application in Drones
• Energy Harvesting for Extended Flight Time

SESSION 5 – ADDITIVE MANUFACTURING AND 3D PRINTING

The session was chaired by Dr Murugaiyan Amirthalingam, Associate Professor, IIT Madras. He gave a basic explanation of the concept of ‘Additive Manufacturing’ to the audience. He said that since Additive Manufacturing (AM) and 3D Printing Technology industry were still in nascent stage, it was the right opportunity to take the lead. He mentioned possibility of adapting additive manufacturing and 3D printing for engineering and biomedical applications, automobiles, etc, in addition to defence. He brought out the benefits of metal additive manufacturing in terms of material and energy saving and design freedom and its attributes of being a fully automated operation with limited skilled manpower requirement to realise from digital to physical form without any part-specific tooling requirements. However, he said that the existing “print-ready” alloys cannot cater to the diverse and growing needs of metal AM, especially in the defence sector, and that true benefits of metal AM can only be realized by developing more AM-friendly high-performance alloys.

V Srinivas, Scientist E, DMRL, DRDO spoke about Additive Manufacturing of Metallic Components for Defence Applications. He started by explaining the concept of Metal Additive Manufacturing. He brought out the advantages of metal additive manufacturing in defence sector specifically reduced product development lead time, reduced dependency on supply chain, manufacturing of critical components with complex geometric profiles, Optimized designs for weight reduction and reduced assembly of parts, manufacture of multi-material components and manufacture of parts with enhanced functional properties and performance.

He gave examples of additive manufacturing being done in the field of aviation and aerospace by GE, Airbus, P&W and NASA. In India, some components for the IAF have been manufactured using AM which have subsequently been certified by CEMILAC.

Today, DMRL is working on the design of new super alloys (alloys by design – ABD) using AM and on developing a test methodology for all the processes.

Capt (Dr) Nitin Agarwala, Senior Fellow, CENJOWS covered the aspects of 3D Printing for Ship Repairs. He began by explaining what AM is and then indicated how AM was slowly being introduced in the maritime sector. For ships, while the US and the US Coast Guard have installed printers onboard, they have used them to print small parts. He showed the cost advantage achieved and that the product manufactured was limited to a non-load bearing member as load bearing members required classification approval process which was still to be defined. He said that since AM had merit and was a sure way to encourage a circular economy, its acceptance would require more work but was a future technology for use on board ships.

Ram Kumar Krishnan, from Intech Additive Solutions covered the subject of Metal Additive Manufacturing through Ultrasonic Atomisation Technology. He indicated that powder quality, handling, purity and manufacture was a challenge for the industry for which Intech had developed solutions. He indicated that while there were a large number of metals, only 50 of them had been atomized to date and small MOQ (minimum order quantity) was a hold point for atomizing more metals. In this effort of manufacturing metallic AM powders, Intech has collaborated with a Polish firm Amazemet and was using ultrasonic atomization, which is considered the best process of manufacturing atomized metallic powder for AM.

S Murali Shankar, Managing Director, Super Auto Forge, covered the subject of Application of Additive Manufacturing in Industries. He provided an insight on manufacturing cold forged parts which is his company’s strength area for the last 50 years. Recently, they have moved to AM wherein they are manufacturing warm forging tools using AM. Such parts can be now manufactured in 78 hours as against 4-6 weeks required in conventional manufacturing process. The printed part has a greater life as internal cooling has been provided to the forged tool. He mentioned that the main challenge in AM is the cost of powder, reducing the build time of parts, increasing productivity and the need for post processing.

The last speaker Sachin Suramwar, from Gasptops briefed the audience on Metal Scan (on-line oil debris sensor providing real-time health monitoring of bearings and gears), Blade Monitor (on-line sensor mounted on engine fan case providing full-time/ real-time detection of blade distortion or cracking) and Chip Check (automated chip detector analyser deployable at the flight line/ maintenance bay) for monitoring equipment health.

Concluding Remarks. Lt Gen Sunil Srivastava, Director CENJOWS summarised the key takeaways of the seminar where he highlighted the need to finding indigenous solutions to the services’ specific requirements urgently in order to overcome the challenges faced in customising the hardware sourced from abroad in preparing the special matreials for defence usage. He said that we need to have a long term strategy in maintaining the assured supply of special materials during war and peace.

The post EVENT REVIEW – Advanced Materials for Defence & Aerospace 2023 appeared first on IMR.

Advanced materials are used in the main structure of aircraft, helicopters and spacecraft as well as and aeroengines due to their special properties in terms of their performance and applications. These include special metal alloys of aluminum, titanium, magnesium, steel, and superalloys, as well as polymers, composites and wood.

The event will focus on special materials for aerospace, shipbuilding, ballistic protection, missiles & space, weapons systems & ammunition, combat vehicles and electronics & sensors.  In addition, there will be discussions on  Smart Materials, Additive Manufacturing and 3D Printing for defence & aerospace applications.

Aerospace Industry

Constant pressure for greater fuel efficiency is forcing aerospace manufacturers to find ways to incorporate new and existing materials that had once been considered impractical to machine.

Forty years ago, aluminum dominated the aerospace industry. Other new materials such as composites and alloys were also used, including titanium, graphite, and fiberglass, but only in very small quantities. Times have changed. Most of the non-critical structural material now consist of even lighter-weight carbon fiber reinforced polymers (CFRPs) and honeycomb materials. For engine parts and critical components, there is a push for lower weight and higher temperature resistance for better fuel efficiency.

Aeroengines ultimately determine fuel efficiency. The challenge is to find materials that will withstand temperatures as high as 3,800°F (2,100°C). The melting point of current super alloys is around 3,360°F (1,850°C).

To meet these temperature demands, heat-resistant super alloys (HRSAs), including titanium alloys, nickel alloys, and some nonmetal composite materials such as ceramics, are now being brought into the material equation. These materials are difficult to machine. There is also a high process risk in machining aerospace parts.

Weapons Systems

Special steel grade is used for artillery gun barrel forging, known for exceptional combination of tensile strength, ductility and toughness. Breech blocks are heavy wall thickness components that require the right steel grade choice to guarantee homogenous mechanical properties throughout the component.

Metal powders are used for additive manufacturing and 3D-printing of manufactured parts for armoured vehicles and artillery applications.

Composites

Composite materials reduce weight and increase fuel efficiency while being easy to handle, design, shape, and repair. They can be used for wing and fuselage skins, engines and landing gear. Pre-formed one piece composite components – lightweight and strong – reduce the number of heavy fasteners and joints.

Ceramic-matrix composites (CMCs), which are emerging in practical use after decades of testing, offer low density/weight, high hardness and, most importantly, superior thermal and chemical resistance.

Smart Materials

Smart materials, also known as intelligent or responsive materials, are used in a variety of applications such as sensors, transducers, artificial muscles and electrically activated polymers (EAP).

Additive manufacturing

Additive manufacturing innovations are being utilized to increase the current level of capability and reduce the cost of parts, in order to deliver greater operational flexibility and further enhance the defence industrial base. Utilizing additive manufacturing technologies to improve military readiness

3D printing materials and processes give military commands and defence agencies the opportunity to modernize their supply chains at scale, increase the size, weight and power (SWAP) of their platforms/weapons systems and enable efficient replacement of parts in a shorter time frame.

Indian Scenario

India continues to develop metallic and composite materials with ever-increasing performance, but there are only a few serious players. New companies are accelerating this evolution of new materials, advancements in machining and cutting technology give manufacturers unprecedented access to materials previously deemed impractical or too difficult to machine. New material adoption is happening exceptionally quickly in aerospace.

Future Scope

Some advanced materials are already well known as groups like polymers, metal alloys, ceramics, semiconductors, composites and biomaterials. Even more impressive product groups like carbon nano materials, activated carbon, titanium and others are expected in the future. Other areas of new materials research include spintronics, amphiphilic materials, superconductors and advanced engineering polymers.

The post EVENT PREVIEW – Advanced Materials for Defence & Aerospace 2022 appeared first on IMR.

Advanced materials are used in the main structure of aircraft, helicopters and spacecraft as well as and aeroengines due to their special properties in terms of their performance and applications. These include special metal alloys of aluminum, titanium, magnesium, steel, and superalloys, as well as polymers, composites and wood.

The event will focus on special materials for aerospace, shipbuilding, ballistic protection, missiles & space, weapons systems & ammunition, combat vehicles and electronics & sensors. In addition, there will be discussions on Smart Materials, Additive Manufacturing and 3D Printing for defence & aerospace applications.

This event will create a synergetic collaboration between all stake holders – Armed Forces, R&D, Industry and Academia to identify and develop a family of affordable, competitive, reliable and high-performance materials and process technologies which are relevant for defence and aerospace applications.

Disruption in Global Supplies

The disruption of supply chains across the globe due to the COVID-19 pandemic has emphasised the need for self-reliance, especially in strategic sectors and indigenous development and manufacturing of materials (including special alloys).

For domestic manufacturers, the opportunities in the defence manufacturing sector have grown over the last few years. Achieving indigenisation of some critical spares and platforms has been one of the main cogs in this growth. But, despite achieving self-reliance in spares and platforms manufacturing, India still has a large import bill of raw materials.

As per recent estimates, India imports approximately Rs 14,000 crore ($2 billion) worth of critical materials annually. Domestic production of these materials can reduce the import bill as well as decouple strategic military assets from geo-political uncertainties.

Aerospace Materials

Special Materials for Defence & Aerospace
Alpha-beta titanium alloy
Aluminium 2000, 5000, 6000, 7000, 8000 series
Carbides (boron and silicon),
Ceramic Matrix Composites (CMCs)
Ceramics Alumina
Cobalt based superalloy (UNS R30605,R30035, R30783)
Cupro-nickel alloy AMS 4596-C72900
Cupro-nickel alloy AMS 4597-C72900
Cupro-nickel alloy AMS 4598-C72900
Grade 1 Aerospace grade titanium
High grade silicon
Iron based superalloy (UNS N08800, N08825, S66286)
Maraging steel
Maraging steel 200, 250, 300, 350
Nickel based superalloy (UNS N06600, N06617, N07750)
Ship building steel
Special grade steel 15CDV6
Special grade steel 4620, 6150, 8640
Special grade steel AISI 4130, 4140, 4330, 4340
Special grade steel MDN 174
Titanium alloy
Titanium Alloy 6AL-6V-2Sn-Ti
Titanium Alloy Grade 5
Titanium Alloy Ti-6Al-4V (UNS R56400)
Titanium Alloy Ti-6AL-4V ELI
Titanium sponge
Alpha and near alpha alloys
Tungsten alloy AMS-T-21014, AMS 7725
Cupro-nickel alloy AMS 4640-C63000
Cupro-nickel alloy AMS 4590-C63020
Special grade steel 15-5PH
Special grade steel 17-4 PH, 17-7PH
Special grade steel HP-9-4-20
Special grade steel MDN 11-10 PH

Constant pressure for greater fuel efficiency is forcing aerospace manufacturers to find ways to incorporate new and existing materials that had once been considered impractical to machine.

Forty years ago, aluminum dominated the aerospace industry. Other new materials such as composites and alloys were also used, including titanium, graphite, and fiberglass, but only in very small quantities. Times have changed. Most of the non-critical structural material now consist of even lighter-weight carbon fiber reinforced polymers (CFRPs) and honeycomb materials. For engine parts and critical components, there is a push for lower weight and higher temperature resistance for better fuel efficiency.

Aeroengines ultimately determine fuel efficiency. The challenge is to find materials that will withstand temperatures as high as 3,800°F (2,100°C). The melting point of current super alloys is around 3,360°F (1,850°C).

To meet these temperature demands, heat-resistant super alloys (HRSAs), including titanium alloys, nickel alloys, and some nonmetal composite materials such as ceramics, are now being brought into the material equation. These materials are difficult to machine. There is also a high process risk in machining aerospace parts.

Weapons Systems

Special steel grade is used for artillery gun barrel forging, known for exceptional combination of tensile strength, ductility and toughness. Breech blocks are heavy wall thickness components that require the right steel grade choice to guarantee homogenous mechanical properties throughout the component

Metal powders are used for additive manufacturing and 3D-printing of manufactured parts for armoured vehicles and artillery applications.

Missiles

Maraging or special stainless steel grades (super-austenitic), aluminum or titanium alloys are used for missile components such as casings and parts. These are supplied as tubes, fForged and closed-die forgings, rolled sheets and bars.

Critical missile components require resistance to corrosion, ductility at negative temperature, excellent weldability and mechanical properties, and extra low or high temperature resistance.

The wide operational temperature range, from cryogenic temperatures to 1100 K, enables this steel to outperform aluminium and carbon fibre structures.

Composites

Composite materials reduce weight and increase fuel efficiency while being easy to handle, design, shape, and repair. They can be used for wing and fuselage skins, engines and landing gear. Pre-formed one piece composite components – lightweight and strong – reduce the number of heavy fasteners and joints.

Ceramic-matrix composites (CMCs), which are emerging in practical use after decades of testing, offer low density/weight, high hardness and, most importantly, superior thermal and chemical resistance.

Smart Materials

Smart materials, also known as intelligent or responsive materials, are used in a variety of applications such as sensors, transducers, artificial muscles and electrically activated polymers (EAP).

Additive manufacturing

Additive manufacturing innovations are being utilized to increase the current level of capability and reduce the cost of parts, in order to deliver greater operational flexibility and further enhance the defence industrial base. Utilizing additive manufacturing technologies to improve military readiness

3D Printing

3D printing and its integration of 3D printing onto military structures and weapons systems can bolster materiel readiness. 3D printing materials and processes give military commands and defence agencies the opportunity to modernize their supply chains at scale, increase the size, weight and power (SWAP) of their platforms/weapons systems and enable efficient replacement of parts in a shorter time frame.

Indian Scenario

India continues to develop metallic and composite materials with ever-increasing performance, but there are only a few serious players. New companies are accelerating this evolution of new materials, advancements in machining and cutting technology give manufacturers unprecedented access to materials previously deemed impractical or too difficult to machine. New material adoption is happening exceptionally quickly in aerospace.

Future Scope

Aluminum alloys still lead in aerospace materials but their share in the aerospace materials is expected to decline in future owing to the increasing use of composite materials.

Some advanced materials are already well known as groups like polymers, metal alloys, ceramics, semiconductors, composites and biomaterials. Even more impressive product groups like carbon nano materials, activated carbon, titanium and others are expected in the future. Other areas of new materials research include spintronics, amphiphilic materials, superconductors and advanced engineering polymers.

The post Event Preview: Advanced Materials for Defence & Aerospace 2022 appeared first on IMR.

Wipro 3D is the metal Additive Manufacturing (AM) business of Wipro Infrastructure Engineering (WIN). “The Wipro3D manufactured components shall be installed in HAL manufactured helicopter engines”, the statement said.

The post Wipro 3D and HAL to Collaborate for 3D Printing appeared first on IMR.