engineered coatings for composites & polymers used in defence & aerospace: now & the...

Engineered Coatings for Composites & Polymers Used in Defence & Aerospace: Now & the Future

Hamburg: 10-11 February 2010

Graham Armstrong FIMFTechnical Sales Manager

Engineered Coatings & Coatings for Engineering

Indestructible

The Company and Our Products

Birmingham Based SME; In Existence Since 1978Suppliers of Coatings to Aero Engine, Airframe,Aero Ancillaries and Other “High Tech”IndustriesApprovals to: AS9100; ISO9001; ISO 14001Stocking Facilities in:- UK; US; France; India; Singapore; Saudi-ArabiaRepresentation Additionally in:- Germany; Belgium; Holland; Scandinavia; Switzerland; Romania & Eastern Europe; Italy; Russia; Israel; Export to Over 40 Countries From UK Main Warehouse

Facilities at UK Base Full Development & Quality Control Laboratories Innovative Development Team to Design New Coatings to Meet Ever Increasing Technical Requirements Full Product Manufacturing Total Commercial & Technical Back Up Teams to Support Distributors and Clients Full Product Stocking Full Export Packing & Despatch Team

Major Customers/ApprovalsRolls RoyceTurbomecaITPGE SikorskyMeggitt ABSHAL IndiaMessier DowtyHoneywellAirbusMcDonnell Douglas Boeing

OEM & Overhaul: In House &

Pratt & Whitney (PWA/CPW)MTU Germany IAEAllied SignalEurocopter BAe SnecmaGoodrich Hamilton SundstrandAgusta-WestlandHAESL/SAESL/TAESL

their Suppliers/Contractors

Product TypesOrganic Paints and Coatings Including ;

Epoxy ; Polyurethane; Acrylic ; Silicon ; Silicate ; Polyimides ; blends and others.Inorganic and Sacrificial Coatings ;

Diffusion and Ceramic Products Dry Film Lubricants Intumescents / ”Thermal Barriers “Primer-filler Coatings for Composites

Typically, Coatings Must Resist:

High Heat: >500-600oCHigh Chemical Attack: Skydrol ;

de icers etcErosion: Rain & ParticleCorrosionHeat & Thermal ConductivityFuel and Lubricants

COATINGS FOR COMPOSITESTHE CURRENT STATUS

Initial Work

Intumescent System for Helicopter

Doors & Hatches

Coatings for Automotive Use (Motor

Cycle Fairings; Small Car

Components)

RECENT DEVELOPMENT PROJECTS

COMPOSITE AIRFRAMED VEHICLES

ELASTOMERIC COATINGS

INTUMESCENT & THERMAL BARRIER COATINGS

Composite Airframed Vehicles

Fully Composite

Airframe

Composite Rotor

Blades

Resin Rich/Weak

Surfaces

Specifications

HAL DHRUV ADVANCED LIGHT HELICOPTER Low VOC 2K Epoxy

Primer-Surfacer

Low VOC 2K Epoxy

Lightweight Spray

Primer-Filler

2K Epoxy “Putty”

(Localised Use)

Low VOC 2K PU

Finishes


HAL DHRUV ADVANCED LIGHT HELICOPTER MPC 50015-R3 Primer-

Surfacer on Majority

of Airframe

MPC 50019-R3

Lightweight Filler on

Engine Firewall & on

Engine Exhausts

IP6 PU Finish (Matt IRR Camouflage Colours)


HAL DHRUV ADVANCED LIGHT HELICOPTER

Elastomeric PU CoatingsBenefits

Erosion Resistance

Flexibility

Exterior Durability

Issues

Application

System Adhesion

Areas of Use

Engine Nose Spinners

Propeller Blades

Radome Coatings

Elastomerics-Recent Projects

Adhesion Failures in Use

Causes felt to be:

Base Coat

Application

UV Resistance

ENGINE NOSE SPINNERS

• Investigative Work

• Clear or Pigmented Base Coat

• Supply of “User Friendly” 2 Component System

• Integration of UV Absorbers

Epoxy BasecoatSystem PU Colour PU System

Epoxy Paint Condition Sample Ref

Bell Peel Result Pull off resultAverage SD Average SD

Clear Clear

Standard

Part Cure 4T1 UV Exposed 159.50 9.26 66.67 20.82

As received 171.50 5.00 54.00 8.94

Full Cure 4T2 UV Exposed 166.73 23.71 43.33 11.55

As received 176.67 32.93 59.00 14.32

UVStabilised


As received 216.67 19.47 57.50 9.87


As received 224.17 11.25 56.67 16.33

Black Clear

Standard


As received 195.83 17.15 68.33 29.44


As received 164.92 26.66 60.00 15.49

UVStabilised


As received 212.50 11.83 63.00 13.96


As received 224.58 24.26 70.00 17.89

Aluminium Clear

Standard


As received 197.08 21.99 68.00 13.78


As received 170.50 27.05 60.83 17.44

UVStabilised


As received 207.08 14.27 77.50 17.25


As received 231.67 27.55 69.17 22.45


TEST CONCLUSIONS

Use of a 2K Epoxy Base Coat Solves Adhesion Issues

Clear Base Coat Better than Black/Aluminium

Use of UV Absorber Improves Both Adhesion & Clarity

System of Clear low VOC 2K Epoxy Basecoat, Plus UV Stabilised 2 Component Elastomeric Now Adopted and Written into Specification

ENGINE NOSE SPINNERS


Similar Issue: Variable adhesion of System-Epoxy Base Coat + Elastomeric PU Topcoat

However before our involvement, client was sourcing various components from differing suppliers. All products met individual specs, but combination gave varying results

PROPELLER COATINGS


PROPELLER COATINGS

System Developed:

Low VOC 2K Epoxy Basecoat

Low VOC 2K Elastomeric PU

Single Source Supply

Products Balanced so 100% Adhesion

Additional Benefit:

Use of low VOC products gave

>1/2 tonne reduction in VOC Emissions


RADOME COATINGS

Specific Requirements:

Erosion Resistance

(Rain & Particle)

Electrical Transparency

Client Issues

Current Product Exhibits “Reversion”

Developed System:

Low VOC 2K Epoxy Seal Coat (Green Tinted)

Specially Pigmented 2K Elastomeric PU

Meets Erosion

Resistance to SAE-AMS

C-83231 & Client Electrical

Transparency

Intumescent Coatings

Increasing Use of Composites Present

New Challenges for Fire Protection

Requirements for Both “External” &

“Cabin Interior” Systems

Each Require Differing Approaches


CABIN INTERIOR SYSTEMSBoth Decorative & Functional Requirements

Main Requirements:

Technical: Non Burn Coatings

Low/No Smoke Release

(FAR 25853 Specification)

Hardness/Durability

Decorative: Colour & Finish Continuity

Textured Finish


CABIN INTERIOR SYSTEMS Developed System:

Low VOC 2K Epoxy Primer-Filler (Low Weight; Thermal Barrier

Effect)

Low VOC 2K PU; Non-Burn, low Smoke Emission

Nano Modified for Surface Hardness


CONTROL BOXES-RECORDERS Traditionally Metal Construction

Moving to Carbon Fibre Epoxy Composite

(Weight etc)

Within Airframe But Usually Outside Passenger

Environment

Requirement to Protect From Fire for Minimum 5

minutes

Requirement to Keep Interior Components Below

350oC (662oF)


CONTROL BOXES-RECORDERS Project with Prime Airframe Manufacturer

Three Alternative Systems Evaluated:

Substrate: Cycom 5215 T650 6K-135 5HS Prepreg

Seal Coat: Low VOC 2K Epoxy Sealer (Green Tinted)

Intumescent: 1.) IP 1265 Thermal Intumescent

2.) Combination IP1265/IP9189

3.) IP 9189 Full Intumescent

Top Coat: Low VOC 2K Epoxy Low Flame Spread Finish


CONTROL BOXES-RECORDERS Coating Systems

Clean Composite with Isopropanol

Apply Green Tinted Seal Coat to Nominal 20 microns

Apply Multi Coat Intumescent to Nominal 350 microns

Apply Finish Coat to Nominal 30 microns

All Coats Cured at 80oC (176oF)

All Panels Allowed 7 days Stabilisation Before Burn Test


CONTROL BOXES-RECORDERSTest Procedure

(to follow set up in BSX 37)

Heat Source: Rothenburger Superfire 2 Torch

Flame Temperature: 1060oC (1940oF)

Flame Applied Directly to Coated Side of Test Panel for 2/5 Minutes

Thermocouples Mounted at Flame/Panel Interface and on Reverse of Panel behind Burner

Intumescent CoatingsCONTROL BOXES/RECORDERS


CONTROL BOXES-RECORDERSIntumescence Values

System 1 System 2 System 3

2 Min 5Min 2 Min 5Min 2 Min 5Min

Height of Char (mm) 9.46 9.95 9.52 9.55 12.28 11.38

Original FT (µm) 350 350 334 334 333 333

Degree of Intumescence (Ratio)

26.00 27.40 27.50 27.60 35.90 33.20

Front View System 1 System 2 System 3

2 Minute Burn

5 Minute Burn

Side View System 1 System 2 System 3

2 Minute Burn

5 Minute Burn


CONTROL BOXES-RECORDERSReport/Comments

All Three Systems Met Original

Requirements

IP 1265 Thermal Intumescent Gave Off

Slightly More Smoke

IP 9189 Selected For Use

IN MOULD PRIMER APPLICATION

In Mould Primers Originally Researched in

Conjunction with Major Automotive

Manufacturer

Being Investigated With Primes in

Aerospace

Has been found to be Successful

with both Injection Systems and

Pre-Preg Layup.

In Mould Primers Product:

Fast Set Up Low VOC 2K Epoxy Surfacer

Process

Apply Epoxy Compatible Mould Release

Spray Apply Primer to Mould Surface

Cure Primer; Either Force Cure or Air Dry

Lay Up Pre-Preg or Fibre Blankets/Inject

Cure as per Normal Process (Autoclave)

Break Mould

In Mould Primers Benefits

Very Even Pre-Primed Surface (Primer

Surface Mirrors the Surface of the Mould)

No Resin Weak Surface Areas

No/Minimal Additional Hand Filling

Faster/Simpler Finishing Process

EXCITING NEW DEVELOPMENTS

Electrical Conductive Coatings

UK KTN (Institute

of Materials)

Possible FP 7

project

Use of Piezo

Electric Cells for

Aircraft De-Icing

Possible Use of

Nano Materials

Bruisable Coatings Damage to

Composite not

always visible

(different to metal)

Danger of

structural

weakening not

being apparent

Investigation into

“Bruisable”

Coatings

Possible Use of

Nano to Act as

“Indicator”

Very Early Stage of

Development -

Watch this space!

Increased Hardness & Resistance Properties

Requirement for

Improvements in:

Surface Hardness/

Erosion Resistance

Heat Resistance/

Intumescence/Thermal Barrier

Chemical Resistance

Increased Hardness & Resistance Properties

Alternative Solutions:

Alternative Cure

Methods on Heat

Sensitive Substrates

Formulation of Cold/

Low Temp Cure

Products With

Increased Performance

Environmental/Legislative Issues

REACH

SVHC’s

Ongoing Restrictions

Solvents Directive

HAPS

CLP

GHS

CrVI Elimination

CRIII Elimination

VOC Reduction/

Elimination

Example: Propeller Manufacturer Discussed Earlier:

VOC Reduction of

>1/2 Tonne

For more information please contact our technical department

+44 (0)121 702 2485

Outside UK office hours please use the form at: -

www.indestructible.co.uk/form

engineered coatings for composites & polymers used in defence & aerospace: now & the...

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