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Aluminium lightning protection for composite aircraft

TWI has been working with AVIC Composites Corporation (ACC) to develop a Lightning Strike Protection (LSP) system for composite aircraft.

ACC approached TWI as it has significant experience in developing thermal spray aluminium (TSA) coating technology for the protection of polymer composite aerospace structures from lightning strike. As a result, TWI developed a well-defined thermal spray coating procedure for the application of LSP coating systems on carbon-fibre reinforced polymer (CFRP) aircraft for ACC.

In the project, TWI compared the ACC and LSP systems and validated procedures for application onto ACC carbon fibre reinforced polymer used in commercial aircraft manufacture.

The work involved studying the effects of process parameters on coating performance on carbon-reinforced polymer, including surface preparation, process/target efficiency, coating microstructure, roughness, oxygen content, adhesion and thermal shock resistance. The lightning strike performance was also evaluated.

The TWI project team identified the process parameters that have the greatest influence on key coating characteristics, and provided ACC with a well-defined thermal spray coating procedure for application of LSP coating systems for CFRP aircraft.

On completion of these trials ACC installed a three-stage automated facility, comprising grit blasting, thermal spraying and painting for the application of coatings on composites for lightning strike management capability, and work continues to move the process up the technology readiness level scale for manufacturing.

For more information, please email contactus@twi.co.uk.

Avatar Dr Melissa Riley CEng FIMMM FWeldI Consultant, Surface Engineering

Dr Melissa Riley is a Consultant within TWI’s Metallurgy, Corrosion and Surfacing team and has >25 years experience in surface engineering with 22 years of service at TWI. She has worked on a wide range of projects for TWI’s Industrial Members relating to the development and application of thermal spray coatings, and other coating technologies. Prior to joining TWI she worked on PVD and CVD coating technologies for orthopaedic applications.

Her work has included application and performance evaluation of wear and corrosion resistant coatings, ceramic coatings, bearing materials and more novel coatings and applications, including leading TWI’s work on the development of coatings on composites. Melissa has also led TWI’s thermal spraying and coating evaluation capability development over the last 15 years, including installation of thermal spraying systems, surface profilometry equipment, and erosion test facilities, along with the creation of a (£0.5M) large scale coating facility (LSF) which now houses TWI’s cold spraying systems and thermal spray coatings at scale. This is supported by robot offline programming capability to support upscaling and manufacturing development.

Melissa is a Chartered Engineer and Fellow of the Institute of Materials, Minerals and Mining and Fellow of The Welding Institute. She also sits on the Management Committee for the UK Thermal Spraying and Surface Engineering Association (TSSEA), which issues the Code of Practice for Thermal Spraying, and also BSI STI/040 Thermal Spraying and Thermally Sprayed Coatings Committee.

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