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