The European foundry industry in a state of upheaval – new opportunities from the defence sector
The European foundry industry is currently under considerable pressure. Several factors are weighing on the sector: the transition to climate-neutral production, the crisis in the automotive industry resulting from high energy prices, restrictive EU regulations, geopolitical tensions and far-reaching market changes, increasing competition from China, and widespread social uncertainty leading to a corresponding reluctance to invest.
To compensate for the loss of traditional sales markets, many foundries are turning their attention to new markets – particularly in the automotive sector. Global conflicts and tensions have led to massive investment in defence, rearmament and aerospace programmes. In many EU countries, substantial funds are available for this purpose – what is crucial now is swift action and the implementation of new production strategies.
In which sectors are castings in particularly high demand?
The answers lie in the specific material properties and manufacturing processes:
- Steel casting
Relevance: Very high
Typical applications: Armoured and tracked vehicles (road wheels, gearbox housings, chassis components), gun barrels, gun mounts, breech blocks and high-load structural components in ships and submarines.
Advantages: High strength and toughness, wear and impact resistance, and good weldability.
- Investment casting (Precision Casting)
Relevance: High
Typical applications: Turbine blades for aeroplanes and helicopters (nickel-based superalloys), precision components for rockets, drones and guided missiles, as well as components for optical and electronic housings.
Advantages: Very high dimensional accuracy, intricate geometries, excellent surface quality and the ability to process complex, heat-resistant materials.
- Iron Casting
Relevance: Medium to high (particularly for ground vehicles)
Typical applications: Engine blocks, gearbox housings, steering knuckles, brake discs and drums for armoured vehicles and lorries, as well as ballast and counterweights for mobile systems.
Advantages: Cost-effective production, high wear resistance and good vibration damping.
- Light-metal casting (aluminium, magnesium, titanium)
Relevance: Very high (in aerospace, increasingly in land vehicles)
Typical applications: Structural components for aeroplanes, helicopters and drones; housings and mounts for radar and weapon systems; and titanium investment casting for high-stress aerospace and naval components.
Advantages: Low weight combined with high strength, corrosion resistance (relevant for the navy and air force) and greater energy and fuel efficiency.
Without casting, there is neither safety nor defence
- Steel casting is ideal for tanks, artillery and ships, where extreme loads and protection are required.
- Investment casting enables precision for aerospace, rocket and drone technology.
- Iron casting remains indispensable for engines, chassis and robust vehicle components.
- Light metal casting is a key technology for modern aerospace and lightweight construction concepts.
European foundries should adapt their future prospects in line with their capacities and process technology. It is important to make conscious use of existing capabilities, to invest strategically and to enter into partnerships with OEMs and system integrators. Only in this way can the sector make a sustainable contribution to safeguarding industrial expertise and national defence.