Specialty Powders Take Center Stage in India's Ambitious Plan to Keep Su-30MKI Fleet Flying

A Granular Shift in Engine Sustainment

India's quest to reduce its Su-30MKI fleet's reliance on foreign engine-maintenance inputs has reached an unprecedented level of specificity. The Department of Defence Production's newly announced sixth Positive Indigenisation List goes beyond conventional components, drilling down into the very raw materials that keep the AL-31FP turbofan's most heat-stressed sections operational. This latest notification signals a strategic pivot toward mastering the foundational materials layer of military aviation sustainment.

Breaking Down the Sixth PIL

The Ministry of Defence formally unveiled the sixth Positive Indigenisation List this week, encompassing 405 strategically significant items with a projected business value of Rs 3,070 crore. The catalogue includes Line Replaceable Units, sub-systems, sub-assemblies, spares, components, and raw materials. Of these, 389 items are associated with Defence Public Sector Undertakings, while 16 are designated for the Indian Coast Guard. Named platforms span the Advanced Light Helicopter, Light Utility Helicopter, Su-30MKI, and Tejas Light Combat Aircraft. The list also covers the AL-31FP engine itself, along with armoured vehicles like the T-72, T-90, and BMP-II, and missile systems such as Konkurs-M, Invar, and MRSAM.

The Critical Role of Specialty Powders

Embedded within the engine-related entries are two raw materials that punch far above their weight: cobalt powder of BK-25 grade and nickel-chromium powder. These alloy feedstocks are essential for thermal spraying processes applied to turbine components that endure extreme heat and mechanical stress. In operation, the powders are propelled through a plasma or high-velocity oxygen-fuel spray gun, where they are melted or softened and accelerated onto worn surfaces. This builds up a dense, protective coating that restores blades, seals, and other hot-section hardware to serviceable tolerances. This technique is central to life-extension work on turbine parts that cannot be replaced wholesale without prohibitive expense, allowing overhaul facilities to refurbish rather than scrap critical components.

Why This Matters for the Su-30MKI Fleet

The AL-31FP engine has been the workhorse of the Indian Air Force's air-superiority fleet for more than two decades. Historically, it has depended on a consistent supply of overhaul consumables from Russia. Any interruption to that supply chain—whether from sanctions-related friction, logistical bottlenecks, or cost escalation—directly impacts engine turnaround times and fleet availability. By encouraging domestic industry, including MSMEs, to develop these powders through the DDP's SRIJAN portal and the Make procedure, the government is addressing a vulnerability that exists well beneath the level of the engine itself, within the materials ecosystem that sustains it between major overhauls.

A Maturing Indigenisation Ecosystem

The broader push for self-reliance has gained substantial momentum since the first Positive Indigenisation List was issued. According to the Department of Defence Production, more than 33,000 defence items have been offered for indigenisation via the SRIJAN portal as of June 2026, including over 5,000 items across the first five lists. More than 15,700 items have been successfully indigenised to date, resulting in an estimated Rs 9,000 crore of import substitution over the past five years. Defence Public Sector Undertakings have also placed close to Rs 10,000 crore in procurement orders with domestic vendors, including in-house production, up to March 2026.

A Strategic Evolution

The inclusion of thermal-spray powders alongside larger structural and electronic components in the sixth list reflects a maturing indigenisation strategy. It demonstrates a shift beyond the more visible LRUs and sub-assemblies into the specialty materials layer, one that directly influences how quickly and affordably India can keep its existing Russian-origin fleets operational without depending on external suppliers for even the smallest inputs of the maintenance cycle.

Key Takeaways

• The sixth Positive Indigenisation List includes 405 items worth Rs 3,070 crore, with 389 for DPSUs and 16 for the Indian Coast Guard.
• Cobalt powder of BK-25 grade and nickel-chromium powder are targeted for indigenous development to support thermal spraying of AL-31FP turbine components.
• The list covers platforms including Su-30MKI, Tejas LCA, T-72, T-90, BMP-II, Konkurs-M, Invar, and MRSAM.
• Over 33,000 defence items have been offered for indigenisation, with more than 15,700 successfully indigenised, translating to Rs 9,000 crore in import substitution over five years.
• DPSUs have placed nearly Rs 10,000 crore in domestic procurement orders up to March 2026, underscoring the scale of the indigenisation push.