Cold Spray of Metallic Coatings on Polymer Based Composites for the Lightning Strike Protection of Airplane Structures

Abstract Unlike their metal counterparts; composite structures do not readily conduct away the electrical currents generated by lightning strikes. Cost reduction and expected production growth of next middle range airplanes require automated manufacturing process polymer components. The development an technology to metallize based for strike protection is aim CO3 project (EU Grant agreement: ID831979). In this study; thermal conductivities composites were achieved cold spray deposition Cu or Al coatings. Critical points be addressed substrate erosion during spray; lack polymer-metal adhesion poor efficiency. Several strategies tested: i) a thin film was cocured at surface before spraying; enable implantation metallic particles in film; helping coating build-up protecting fibers composite. ii) Cold spraying mix powders improve prevent fiber damage. iii) Supercritical Nitrogen Deposition technology; prior mechanically anchor into polymer. Subsequent purely coatings more efficient showed better adhesion. All tested terms strength conductivity.