films and coatings for lightning strike protection -fly ... · -fly lighter, manufacture with...
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Weight Reduction and Manufacturing Benefits of LORD UltraConductive™ CoatingsFilms and Coatings for Lightning Strike Protection
LORD Corporation Copyright 2012
-fly lighter, manufacture with less-
1. A highly conductive epoxy film or coating that utilizes non-nano, commercial materials to protect composite aircraft structures from a direct lightning strike
2. Significant weight reduction compared to conventional expanded metal foil surfacing films
3. An automation enabling technology designed to allow aircraft OEMs to increase throughput and reduce touch-time
4. Recipient of the 2012 Aviation Week Innovation Award in Composites
5. Currently in evaluation and qualificationwith multiple aerospace OEMs and tiers
What are LORD UltraConductive Coatings?
LORD UltraConductive Technology
Highly conductivePolymer Composite
Heat
≥ 100oCEpoxyResin
Non-NanoConductive
Filler
Thermal Conductivity Electrical Conductivity
+ Curative +
Conventional Conductive Epoxy
LORD UltraConductive
Material Carbon Nano-Fibers
Conventional Conductive
Epoxy
LORD UltraConductive Material
LORD UltraConductive Coating Performance
• Lightning Strike Tests: Passes Zone 1A and Zone 2A with no puncture of thin gauge epoxy / carbon laminates
• Weight savings: Direct and indirect weight savings with areal weights of 140 gsm and 190 gsm
• Surface Finish: Improved surface finish over standard expanded metal foil solutions
• Manufacturing: Improved throughput by reducing surfacing steps often associated with expanded metal foils. Offers automation opportunities.
• Secondary Properties: Equivalent or superior to expanded metal foil in tests including: corrosion, wear resistance, paint adhesion, solvent resistance, UV Resistance, thermal cycling and mechanical fatigue.
• EMI Shielding: Enables composites to approach shielding levels of aluminum skin
Lightning Strike Testing
LORD UltraConductive Coating Benchmark (Exp. Cu Foil)
Direct Weight Savings Opportunity
• Estimates based on direct substitution of LORD UltraConductive for standard metal mesh based LSP systems
0
50
100
150
200
250
300
350
Standard CuMesh‐based LSP
Standard AlMesh‐based LSP
LORDUltraConductive
Areal W
eight (gsm)
Expanded Metal Foil Surfacing FilmIsolation layer LORD UltraConductiveCoating
Metal Expanded Foil Benchmarks
Urethane Topcoat (PPG Desothane® CA8000)
vs.LORD
Epoxy Primer (PPG Desoto® 515X349 )
Urethane Topcoat (PPG Desothane® CA8000)
Surfacing Film
Expanded Copper Foil
Carbon Substrate
LORD UltraConductive Coatingfilm, spray
Carbon Substrate
Improve Surface Finish – Reduce Weight and Cost
Expanded Copper Foil After Primer
LORD UltraConductive
Expanded Copper Foil Before Paint
Reduced Material Costs• Less Primer to cover up defects
Reduced Labor Costs• UltraConductive Film is less labor intensive than
competitive LSP materials• UltraConductive Spray enables automation
Film • Drop‐in replacement for expanded foils systems
Spray‐on‐Tool• Easy application of LSP to complex parts• Designed for application directly to female tool surface in the paint shop
LORD UltraConductive Product Forms
SurfacingFilm
LSP Applica‐tion
Carbon Layup & Cure
Inspec‐tion
Prime & Heavy
Resurface
Light Priming and
sanding
Topcoat
Manufacturing with LORD UltraConductive Film
Surfacing Film (ATL or hand-layup)
o Co-cures with composite at 100-177 C (212-350F) in oven or autoclave
o Superior surface finish to expanded foil products
o Enables labor hour reductions
Standard Expanded Metal Mesh Process
LORD UltraConductive Film Process
SurfacingFilm
LSP Appli‐cation
Pre‐bake
Carbon Layup & Cure
Inspec‐tion
Prime & Heavy
Resurface
Light Priming and
sanding
Topcoat
Manufacturing with LORD UltraConductive Spray
Spray on Tool(Manual or automated)
o Designed for use in industry paint boothso Minimizes LSP application time on complex curvatureso Superior surface finish to expanded foil productso Co-cures with composite at 100-177oC (212-350oF) in
autoclave.
Standard Expanded Metal Mesh Process
LORD UltraConductive Film Process
• Mock business jet tail boom– Constructed carbon tool– Part construction performed at reputable composite fabrication
house– Used for evaluating UltraConductive materials in:
• gathering ease of use data • time trials • strike performance on large complex shapes
LORD UltraConductive Spray-on-Tool Example
SurfacingFilm
LSP Applica‐tion
Carbon Layup & Cure
Inspec‐tion
Prime & Heavy
Resurface
Light Primer
Light Sanding Topcoat
Compatibility with Current and Emerging Processes
Common industry autoclave cycles
Oven cure with vacuum bagging
TT and PE Ultrasonic
NDE Industry standard abrasive systems,
primers and paints
*being validated
Manual
Automated film
application via ATL or
AFP*
Automated spraying
Additional Manufacturing Benefits
LORD UltraConductive Film LORD UltraConductive Spray‐on‐Tool
Storage Conditions Same as carbon prepreg Room temperature
Preparation Cuts / slits using standard techniques Standard paint mixer
Conformability Drapes easily over complex shapes Conforms precisely to tools
Forgiveness
Flows slightly during cure to span small gap (~0.5mm); forms smooth transitionswhen overlapped; wrinkles flatten; can be repositioned
Machining Drills without cracking, delaminating, or fouling tool
Repairable using UltraConductive
film or spray Retains original strike protection
LORD Ultra‐
Conductive Materials
Weight Savings
Improved Throughput
Fit into current processes
Equivalent Strike
Protection
Summary