Copper: A strategic material for modern warfare

There is strong precedent for incorporating copper security into policymaking in India.

By Ashmita Sethi 

As India advances its indigenous defence manufacturing capabilities in its quest for Atmanirbharta, copper has emerged as an indispensable material, which enhances the operational effectiveness and the success rate of modern combat platforms. The metal and its alloys have emerged as a linchpin in this technological revolution, with applications spanning electrical systems, directed-energy weapons (DEWs), electromagnetic propulsion, and next-generation armour, that define the next-generation defence platforms.

For instance, the Defence Research and Development Organisation (DRDO) in partnership with Larsen & Toubro-developed Composite Combat Infantry Vehicle (CCIV), represents a landmark achievement. It is also strong contender for the Indian Army's Futuristic Infantry Combat Vehicle (FICV) contract. Since such vehicles require integration of advanced fire control systems, communication networks, and battlefield management systems in the vehicle, they become highly dependent on extensive copper-based electrical infrastructure.

Modern infantry fighting vehicles also rely heavily on sophisticated communication and radar systems to ensure real-time battlefield awareness and coordination with other military units. The reliability of these critical systems depends on the quality and performance of copper-based components that facilitate seamless information exchange even in challenging conditions.

The Tejas Story

In India the indigenously developed Tejas Mk-1A fighter jets, copper wiring constitutes 80% of the aircraft’s electrical network, enabling radar systems with 150 km detection ranges.  The BrahMos missile, which played a critical role in “Operation Sindoor” in the recent Indo-Pak war, is an unmanned payload rocket with a propulsion and guidance system, aerodynamic frame, precision-guided weapons and a warhead. The missile can deliver a 200- to 300-kilogram high-explosive warhead at a cruise speed of Mach 3, uses copper alloys for its electronic systems, wiring, and communication components and in the missile's guidance and navigation systems, ensuring accurate targeting.

Similarly, copper and its alloys -- the aluminium-zinc-magnesium-copper combination-- are used to strengthen structural framework of the Akash missile system such as tail fins and sabot, which provides the necessary strength-to-weight ratio and durability under high thermal and mechanical stress. (4) Its impressive thermal conductivity helps in dissipating heat generated during high-speed flight and propulsion, protecting sensitive electronic and structural elements.

Even the missile’s onboard power supply system depends on copper windings and connectors in batteries, capacitors, and actuation mechanisms thereby ensuring efficient energy delivery to critical subsystems during all phases of flight. Thus, copper underpins the electrical, structural, and guidance capabilities, and directly contributing to its status as a cornerstone of India’s air defence network.

The Copper Advantage in Naval Warships

In the case of naval warships, copper is used in wiring, communication networks, and electrical equipment. The resistance of copper and alloys (such as cupro-nickel, aluminium bronze, and naval brass) to corrosion from seawater makes them ideal for ship hulls, piping, condenser tubes, and other components exposed to harsh marine conditions. (5) Similarly, the INS Visakhapatnam-class destroyers use 12 tons of copper-nickel alloy piping per vessel to withstand saline environments.

Moreover, its superior electrical conductivity makes it the material of choice for power distribution, lighting, control systems, and advanced communication and instrumentation cables on board Indian naval ships. And its low resistance, high-reliability connections for vital systems, including navigation, radar, sonar, and weapons control for naval vessels.

Thus, copper's fundamental properties make it uniquely suited for demanding military applications, where reliability and performance under extreme conditions are paramount. The metal's superior electrical conductivity, thermal properties, and corrosion resistance establish it as a preferred material for various critical applications that require reliable performance and durability.

Hence, there is strong precedent for incorporating copper security into policymaking in India. The rising demand-supply gap can have an adverse impact on the Indian defence sector, given the current precarious situation. While copper consumption has risen from 494,787 tonnes in 2016-17 to 843,941 tonnes in FY2023-24, domestic copper production has seen a steep decline of 60%. resulting in massive imports.

This growing challenge can only be taken care of if there is a move not just through securing greater access to copper ore through partnerships with different countries like those in Africa, South America, Central Asia, but also strengthen the refining industry. Opening new refining capacities is as important as reopening the existing ones, lying unused for years.

It is easy to forget that even in 1996-97, the country was exporting nearly 4.5 million metric tonnes of refined copper, enabling India's downstream finished goods industry to become an $ 18 billion industry. However, the closure of the 4-lakh tonne per annum Vedanta’s Sterlite Copper smelter in 2018, in Thoothukudi, Tamil Nadu, resulted in India’s export plunge by 90 per cent, thereby becoming an importer for the first time in 18 years.  A reassessment of the copper industry’s entire value chain could transform the fortunes of the Indian defence industry in its quest for Atmanirbhartha.

(Ashmita Sethi, Aerospace & Defense C-Suite Leader, is Advisor to Global Aviation Majors.)

Views are personal, and do not represent the stance of this publication.