Due to the Global Situation Leading Steel and Forging Expertise Helps the Armament

New threat scenarios have led to a global rethinking of defense strategies. The demand for tanks, traditional weapon systems, ammunition, and also new systems is increasing, but poses significant challenges for the defense industry. The SHS Group points to its three companies in view of this.

When it comes to the steel and forging tasks required to tackle them, leading German and international defense manufacturers rely on materials and components from the three companies of the SHS Group (SHS – Stahl-Holding-Saar): Aktiengesellschaft der Dillinger Hüttenwerke, Saarstahl Aktiengesellschaft, and Saarschmiede GmbH Freiformschmiede. The unique combination of steel production, heavy plate rolling mill, bar rolling mill, and forging under one roof has made the trio sought-after suppliers for many products in the defense sector for years.

Dillinger Is a Partner of the German Armed Forces

For many years, Dillinger has been supplying Difender armored steels, approved by the Bundeswehr according to TL 2350-000, to leading manufacturers of wheeled and tracked vehicles. In addition to the Bundeswehr standard for German manufacturers, these high-alloy quenched and tempered steels also meet the relevant national and international standards of alliance and NATO partners. Furthermore, Dillinger has obtained numerous customer, project, and government approvals for these armored steels. Today, the company, headquartered in Dillingen, Saarland, sells over ten different Difender grades as per data sheet in thicknesses ranging from six to 150 millimeters (approx. 0.24 to 5.91 in) and in finely graduated hardness levels from 270 to 600 HBW. Nine of these grades are approved by the Bundeswehr according to TL 2350-0000, allowing entire vehicles to be constructed with these grades, virtually covering all requirements. This complete range makes Dillinger the only comprehensively approved supplier in Germany. The armored steels are used equally in both military and civilian applications. The approved production of Difender steels at the two production sites in Dillingen, Germany, and Dunkirk, France, ensures high manufacturing capacity. Difender safety steels are among the safest in the market against ballistic and explosive impacts, providing maximum protection. An exemplary case is Difender 500, the most commonly used and tested safety steel, unique in the market for its thickness of up to 150 millimeters (approx. 5.91 in).

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The Most Weldable Armored Steel

With the same hardness and ballistic requirements, it can generally be processed thinner as proven. This reduced minimum thickness enables weight-optimized designs for fully armored vehicles in both military and civilian sectors. In addition to standard military dimensions, Dillinger can produce Difender armored steels in significantly larger widths (over three meters / approx. 9.8 ft) and lengths (more than 20 meters / approx. 65.6 ft)—ideal for waste-minimized and thus cost-optimized production, even in custom sizes. These custom-tailored armored steel formats in thickness, width, and length make a crucial contribution to security as floor and roof plates for military wheeled and tracked vehicles or building armor at bullet height. At the same time, the largest possible plate dimensions while meeting the strictest flatness requirements open up valuable optimization potential for system components for designers. This is supported by the outstanding processing properties of Difender armored steels. Test series conducted by renowned independent companies demonstrate excellent values in cutting, bending, joining, and mechanical machining. When cold bending, Dillinger’s armored steels achieve minimum bend radii that are among the best on the market. For weldability, Difender is the best in its class.

Very Complex Parts are Possible

Dillinger is also a leader in providing expert support for questions regarding material selection, processing, and design implementation. The experts in technical customer support, who have been familiar with the specific requirements of the defense industry for many years, provide competent assistance to designers. Together, the maximum potential is extracted from the material for each specific application.

In close collaboration with the development departments of all vehicle manufacturers for military applications, Dillinger conducts targeted development work to meet the growing demands with new material grades that were previously unavailable on the market in this form. An example of this partnership with the defense industry is the custom development of Difender 270 for military vehicles of foreign buyers. The alloyed high-strength quenched and tempered steel Difender 600PH is particularly suitable for hot forming processes for the production of very complex components. As Europe’s leading heavy plate manufacturer, Dillinger offers this material in thicknesses of up to 25 millimeters (approx. 0.98 in).

At the customer's request, even greater thicknesses are achievable—initial interest has already been expressed by defense manufacturers. Manufacturers of civilian applications such as cash transport vehicles, limousines, shooting ranges, or building protection for embassies, banks, or government buildings (doors, window frames, etc.) also highly value the in-depth technical consultation from Dillinger’s experts and joint development efforts. Difender safety steels are widely used in both sectors. Research and development based on a deep understanding of metallurgical models and advanced manufacturing processes have long made Dillinger the partner of choice for manufacturers of seafaring vessels, frigates, corvettes, and submarines. For over 30 years, Dillinger has had approval for the submarine steels HY-80 and HY-100. These pressure-resistant grades were specifically developed for pressure hulls and outer hulls of submarines and are approved by renowned customers.

Components for the NATO Naval Sector

With Saarschmiede, another company of the SHS Group has long been a proven supplier for submarine and defense manufacturers. As a world-leading provider of special materials, superalloys, and large plant components, as well as a globally renowned open-die forge, Saarschmiede sets unmatched standards in many areas. The foundation of this success lies in its extensive range of equipment and comprehensive manufacturing processes, from melting and forging to heat treatment, ultrasonic testing, and further processing. Technical consulting, as well as further developments or modifications in collaboration with designers in the defense industry, complete the portfolio. An example of this is the very challenging-to-produce stainless steel grade 1.3964. Saarschmiede also holds a leading global position in the production and further processing of nickel-chromium superalloys Inconel 600 and Inconel 625 in a single source. As an approved supplier, it provides large components made of these alloys to non-German NATO companies. From Inconel 600, Saarschmiede manufactures large pressure vessels that encase the nuclear propulsion systems of warships. Due to the required component sizes, the forge in Völklingen (Germany) enjoys an almost unique position. This prominent role is based on its exceptionally large, globally unique forging units. While in the past, the hulls of nuclear propulsion systems were rolled from nickel sheets and closed with weld seams, Saarschmiede now forges the massive pressure vessels as seamless components. Even for the somewhat smaller pressure vessel hulls for nuclear submarine propulsion systems, Saarschmiede’s seamless forged components remain virtually unrivaled.

Decarbonized Steel is in Demand

The parent company of Saarschmiede, Saarstahl, is one of the world's leading manufacturers of long steel products for a variety of key industries, with locations in Völklingen, Burbach, and Neunkirchen. Renowned defense manufacturers rely on this expertise for the provision of materials for large-caliber, medium-caliber, mortar, and infantry ammunition. For NATO projectiles, Saarstahl produces billets made from materials such as 42CrMo4 and 30CrNiMo8 with diameters of 135, 158, or 160 millimeters (approx. 5.3, 6.2, or 6.3 in) and lengths of 600 or 700 millimeters (approx. 23.6 or 27.6 in). Other grades are also possible upon request. The raw material is produced by Saarstahl Ascoval, a French subsidiary based in Saint-Saulve, using 100 percent recycled steel in the electric arc furnace process (EAF). Compared to conventional steel, which is produced from raw materials iron ore and coal through a blast furnace route with an oxygen converter, this manufacturing process reduces CO₂ emissions by up to 70 percent.

The demand from the defense industry for this decarbonized steel for ammunition is high. In the Saarstahl plants in Völklingen and Nauweiler, the "green" steel, cast into billets, is rolled and further processed. The production of pre-materials for defense manufacturers is done according to customer specifications—either through the forging process, mechanical pressing, or milling from the long product. For example, from bar steel of grade 42CrMo4, the pre-material for the casing of the NATO projectile 155-millimeter large caliber is mechanically pressed. Renowned major manufacturers have approved this product from Saarstahl and ordered it as part of serial contracts. Other applications for Saarstahl's specially developed bar steel qualities for the defense industry include pre-materials for rifle barrels as well as bolts for the chain systems of tanks and armored vehicles.