India's defence sector has reached a pivotal moment, with production hitting ₹1. 5 lakh crore this year and long-term targets set at ₹3 lakh crore. Mission Sudarshan Chakra, the country's most ambitious indigenous air defence programme, will require a full ecosystem of advanced materials, thermal systems, and integrated platforms.Carborundum Universal Limited (CUMI), part of the 125-year-old Murugappa Group is positioned at the core of this shift. It is among the few Indian companies producing zirconia-based thermal barrier coatings for jet engines, ceramic armour for naval helicopters. All of this is delivered within India, supporting the country's goal of reducing foreign dependency and scaling high-value defence exports.In a chat with C&amp;ACER, Mr Subbu Venkatachalam, Head of Defence &amp; Aerospace, Carborundum Universal Limited gives us an insight into how India is building self-reliant supply chains for high-performance defence materials besides a firsthand view of how CUMI's technologies are supporting jet propulsion, and naval protection, amongst other things.What are some of the products manufactured by CUMI, especially related to high-performance coatings and ceramics, and their USP?The USP of engineered ceramics is their ability to combine advanced protection with exceptional performance. This is especially critical in aerospace where civil and military aircraft, especially, are put through some of the most gruelling routines. Our range of technical ceramics goes far above traditional materials when compared on parameters such as mechanical strength, wear resistance, thermal stability, chemical inertness, and electrical properties.An apt demonstration of our expertise in ceramics for defence applications is in armour. With ballistics becoming highly sophisticated and lethal, the best way to bring protection up to speed is to take innovation right to the grain. By engineering ceramics that can withstand highly destructive ballistics, like those from an AK-47, for instance, ensures that military personnel, civilians, vehicles, and assets are ably safeguarded.Right from controlling the particle size and microstructure, our customisable ceramics for body armour deliver on ergonomics, hardness &amp; toughness with the ability to shatter projectiles without harming the soldier, maintain structural integrity even in extreme environments, while being extremely lightweight.Our Reaction Bonded Silicon Carbide, Zirconia Toughened Alumina, and high-purity Alumina ceramics are benchmarked in line with the US Department of Justice NIJ (National Institute of Justice) global standards. We have also patented our Zirconia Toughened Alumina-based composite armour panels that function as add-on armour, especially for combat and other military vehicles. These have been certified as per NATO'S STANAG 4569 qualification and offer added protection for areas vulnerable to projectile hits.High-performance ceramic coatings are invaluable for applications in aerospace, especially to protect critical components in the 'hot section'. Operating at extreme temperatures for prolonged periods, these components – turbine blades and vanes, combustion chambers, turbine housings, exhaust manifolds, and nozzles – are highly susceptible to oxidation, creep, wear &amp; tear, and corrosion. Frequent maintenance, repair, and overhaul can result in unplanned downtime while being prohibitive on the cost front. Hence, robust protection with thermal barrier coatings and wear-resistant coatings can help them function at optimum capacity in harsh environments, without compromising on component health. Our thermal spray powders, the raw material for these coatings, are produced under the CUMIPLAS brand. They include Zirconia-based and Alumina / Alumina-Titania powders. Their USP – low thermal conductivity / high thermal insulation, corrosion resistance, and good thermal shock resistance.With India's defence ambitions on one end of the spectrum and growing demand on the other, CUMI is well-positioned to fulfil one while helping achieve the other.Can you elaborate on CUMI's role in building self-reliant supply chains for high-performance defence materials?The greatest challenge to manufacturing high-performance materials as we look to indigenize and modernize our defence systems is a strongly interconnected domestic supply chain. Self-reliance is all about helping make connections and bridge gaps across the ecosystem so that wide-ranging parameters – whether it is material supply, innovation, cost, tech advantage, or sustainability - can all be addressed.The most crucial role we play here is by being fully backward integrated. This allows us to be self-reliant right from the start - by producing raw materials (grains and powders) for different applications across defence &amp; aerospace in India at our state-of-the-art factories. This is especially true for mission-critical materials for which India still relies on imports – 100% in some cases, such as Yttria-stabilized Zirconia, the base material for thermal barrier coatings.Secondly, challenges such as materials processing significantly drive up costs in the absence of expert processing capabilities. We are also closing the gap in this area, enabling OEMs, integrators, etc., to benefit from such cost advantage.Further ahead, through R&amp;D - in-house at our labs and actively with our academia partners - we are helping develop innovations for Indian prototypes. Through Transfer of Technology (ToTs), we are helping commercialize new technologies at scale for defence. We also ensure all our products are validated, tested, and certified as per Indian and global benchmarks &amp; standards.During the course of manufacturing, our partner-MSMEs who support us with associate components also benefit and scale with us. We collaborate with startups to identify areas for the intersection of pioneering materials and future tech.Beyond component manufacturing, we have also been involved in supporting our OEM partners with forward integration, owing to our intimate knowledge of the product and its application.So, we play several roles to connect the dots across the ecosystem so that ultimately, the greatest advantage is for our soldiers at the frontlines - the most advanced protection that helps save lives.How does CUMI's advanced materials support aircraft performance and naval protection?Our solutions, powered by materials science, span a wide range of protective applications across land-based, aerial, as well as naval systems and platforms.When we look at aircraft performance, this is keenly linked to engine health and capabilities. Ensuring the engine functions at high efficiency, offering superior performance, means protecting critical, high-stress components that help the engine perform reliably.Operating temperatures in the hot section of civil and military aircraft can touch 2000°C in combustion chambers, and even higher with afterburners. CUMI's thermal barrier coatings on 'hot section' components allow engines to operate at elevated temperatures without degrading the underlying or base materials. By enabling high thermal insulation, they ensure minimized heat transfer and thermal stress, support better engine efficiency, lower fuel consumption and reduced emissions. Our dense and tough wear-resistant coatings protect components from oxidation, creep, corrosion, and frequent wear &amp; tear. This directly fulfils two key priorities - keeping occupants safe and extending component life, reliability, and durability.As engine tech becomes increasingly sophisticated, these coatings address the most significant challenges of high cost and frequency of component replacement.In the area of naval protection, ceramics provide the dual advantages of lighter weight, with a high strength-to-weight ratio, and anti-corrosion (in harsh marine environments) when compared to steel. The lighter weight advantage will result in greater manoeuvrability and speed. They are also highly resistant to fire, bullets, and blasts, making them ideal for extremely tough and demanding maritime environments.The range of applications of our products extends from blast- and fire-resistant infrastructure for naval bases and shipyards, retrofitting as well as building modern warships with robust ballistic protection, using improved fabrication techniques to design large, complex structures, as well as lightweight armour for amphibious and armoured vehicles used in naval security operations, anti-skid coatings, and abrasives for naval workshops.Our innovations in fire protection also involve passive measures, including specially fabricated space-and weight-sensitive thermal ceramic blankets. Murugappa Morgan Thermal Ceramics (MMTCL) supplies this product to all major shipyards in India for thermal and passive fire protection of bulkheads, ship decks, engine rooms, exhaust manifolds, and cabin doors.All this not only helps secure ships and crew but also extends the life of expensive components and equipment, making naval operations more agile and efficient.What is your take on public-private alignment across R&amp;D, procurement, and certification in the defence sector?Over the last decade, since Make in India took shape, powered on by several government-led innovation initiatives in defence, public-private alignment has steadily grown. This could be through routes like transfer of technology, collaborations to expand R&amp;D between the triad of government, academia, and industry, partnerships to innovate and refine prototypes, as well as fast-tracking efforts to test and validate as per globally recognized standards. While challenges do exist, there is, across the board, a better understanding and cooperation of the role and expertise of different players in the ecosystem. This has resulted in more aligned working partnerships, enabling faster turnaround cycles and more Indian defence-specific innovations.What is CUMI's R&amp;D role in developing these products?With a legacy and know-how of over 70 years, we have steadily strengthened our R&amp;D ecosystem over the years, blending scientific thinking into our processes to drive innovation and sustainable value creation.We hold 100 patents, 525 trademarks, and 62 designs collectively across CUMI.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/oty7M06r01763447301492/6937639441.jpg" alt="image">So, our team of scientists, researchers, and other experts plays a key role in developing these products by closely working with OEMs as well as end users to assess different criteria. Since we are fully backward integrated, we have strict, complete control over raw material quality. In fact, our R&amp;D team has developed and patented techniques, machines, as well as material formulations to internally evaluate for precision, quality, based on use. We also collaborate with Centres of Excellence across reputed research institutes to actively discover new products, improve formulations, or determine new use/applications.Are there other uses for these defence related products, especially in the industrial protection sector?Absolutely! Advanced ceramics such as Reaction Bonded Silicon Carbide find applications in components for semiconductors/power electronics, chemical processing, furnace/kiln internal parts, feed chambers, pipes, tubes, &amp; chutes conveying abrasive particles, break liners, pipelines carrying highly corrosive material, mechanical seals and bearings, components in coal/power generation.Similarly, Zirconia Toughened Alumina finds applications in manufacturing/metalworking in cutting tool inserts, punch and die components, as well as for cutting &amp; drilling. It also finds use in mining &amp; mineral processing (wear liners, grinding media), cement &amp; power plants (coal mill components, flue gas system parts, kiln furniture), chemical &amp; petrochemical industry (pump parts exposed to acidic conditions, nozzles, plungers &amp; liners in high-wear fluid systems), automotive components (sensors and insulating parts, valve components, sealing faces, wear-resistant inserts), medical industry (hip implants, joint prostheses), surface finishing / polishing (de-burring media, shot peening and polishing beads), and emerging areas like the construction industry (flooring in high-traffic / footfall areas).What is the future of paints for the defence sector (stealth-paints, etc.)There is significant potential for paints that is being explored by the public as well as the private sector.This could be in the area of stealth (graphene and other nanomaterials) to reduce radar signatures, as well as in the area of protection (paints that heighten corrosion resistance, abrasion resistance, enable self-healing, deicing/anti-icing, hydrophobicity, improve durability at sea and against UV rays, etc). With defence modernization progressing at a rapid pace, coupled with the integration of new-age tech and advancements in materials, the use of multifunctional paints will prove revolutionary for the sector.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/oty7M06r01763447301492/4333764333.jpg" alt="image">A brief history of CUMI...Carborundum Universal Limited (CUMI) is part of the 125-year-old Murugappa Group, which has been recognised among the top 10 business conglomerates in India. Established as a tripartite joint venture in 1954, CUMI is a leading materials science engineering solutions provider. We are listed on the NSE and BSE.As a fully backward integrated company, our operations include mining, power generation, fusion, manufacturing, marketing and distribution. Our global team of over 6,200 employees collaborates, innovates, and develops high-quality material solutions across our core businesses - abrasives, electrominerals, industrial ceramics, refractories and energy storage materials – forming the backbone of critical sectors across the globe.With 20 manufacturing facilities across India, our expertise spans diverse industries including engineering, fabrication, auto and auto components, infrastructure, steel, glass, power generation and distribution, defence and aerospace. We have manufacturing operations across 7 countries and serve customers in over 60 geographies.With over seven decades of expertise in materials science, our mission in the defence sector is rooted in a simple but compelling goal: to engineer advanced materials that help save lives on the frontlines. Our high-performance ceramic solutions - designed to meet global standards - are designed for use in body armour and vehicle armour, to protective systems for naval vessels, aircraft carriers, and Air Force helicopters.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/oty7M06r01763447301492/3433396949.jpg" alt="image">As India accelerates its defence modernization, we're focused on building self-reliance through innovation and indigenization of critical materials. This approach ensures not only global quality and precision manufacturing but also cost competitiveness. We're also working hand-in-hand with government agencies and industry partners to co-develop solutions tailored to the specific needs of Indian defence platforms and prototypes.While we're aligned with the country's long-term strategic ambitions, our immediate priority remains clear: to equip every soldier with the best in protection.

CUMI building self-reliant supply chains for high-performance defence materials

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