Gotta remember folks, neither the long sword nor the katana (nor especially the broadsword) were designed to hack straight through iron armor. Traditional samurai katana skills (katori shinto ryu) emphasized aiming for gaps in the armor, especially wrist, face, waist and such. Longswords were actually used more like prybars (at least in the german longsword tradition) and aimed again at the gaps in the armor. In both cases, other weapons were specifically designed for the anti-armor role, and going sword against armor required a fair amount of skill and luck.
What's the sword for? Lightly armored opponents. On most battlefields, most of the fighters can't afford much more than a helmet and chest protector. In that environment, a sword is a good weapon, particularly if you happen to be wearing full armor.
Best,
F
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