Engineered Coatings for Composites

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Engineered Coatings for Composites Polymers
Used in Defence Aerospace Now the
FutureHamburg 10-11 February 2010Graham
Armstrong FIMFTechnical Sales Manager
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Engineered Coatings Coatings for Engineering
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IndestructibleThe Company and Our Products
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• Birmingham Based SME In Existence Since 1978
• Suppliers of Coatings to Aero Engine, Airframe,
• Aero Ancillaries and Other High Tech
• Industries
• Approvals to AS9100 ISO9001 ISO 14001
• Stocking Facilities in- UK US France India
  Singapore Saudi-Arabia
• Representation Additionally in- Germany
  Belgium Holland Scandinavia Switzerland
  Romania Eastern Europe Italy Russia Israel
• Export to Over 40 Countries From UK Main
  Warehouse

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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

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Major Customers/Approvals

• Rolls Royce
• Turbomeca
• ITP
• GE
• Sikorsky
• Meggitt ABS
• HAL India
• Messier Dowty
• Honeywell
• Airbus
• McDonnell Douglas Boeing
• OEM Overhaul In House

• Pratt Whitney (PWA/CPW)
• MTU Germany
• IAE
• Allied Signal
• Eurocopter
• BAe
• Snecma
• Goodrich
• Hamilton Sundstrand
• Agusta-Westland
• HAESL/SAESL/TAESL
• their Suppliers/Contractors

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Product Types

• Organic 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

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Typically, Coatings Must Resist

• High Heat gt500-600oC
• High Chemical Attack Skydrol
• de icers etc
• Erosion Rain Particle
• Corrosion
• Heat Thermal Conductivity
• Fuel and Lubricants

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Coatings for compositesthe current status
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Initial Work

• Intumescent System for Helicopter
• Doors Hatches
• Coatings for Automotive Use (Motor
• Cycle Fairings Small Car
• Components)

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Recent Development Projects
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Composite Airframed VehiclesElastomeric
coatingsINTUMESCEnt thermal barrier coatings
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Composite Airframed Vehicles

• HAL DHRUV Advanced Light Helicopter

• Fully Composite
• Airframe
• Composite Rotor
• Blades
• Resin Rich/Weak
• Surfaces
• Specifications

• Low VOC 2K Epoxy
• Primer-Surfacer
• Low VOC 2K Epoxy
• Lightweight Spray
• Primer-Filler
• 2K Epoxy Putty
• (Localised Use)
• Low VOC 2K PU
• Finishes

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Composite Airframed Vehicles

• 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)

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Composite Airframed Vehicles

• HAL DHRUV Advanced Light Helicopter

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Elastomeric PU Coatings

• Benefits
• Erosion Resistance
• Flexibility
• Exterior Durability
• Issues
• Application
• System Adhesion

• Areas of Use
• Engine Nose Spinners
• Propeller Blades
• Radome Coatings

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Elastomerics-Recent Projects

• Engine Nose Spinners

• Adhesion Failures in Use
• Causes felt to be
• Base Coat
• Application
• UV Resistance

• Investigative Work
• Clear or Pigmented Base Coat
• Supply of User Friendly 2 Component System
• Integration of UV Absorbers

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Epoxy Basecoat System PU Colour PU System Epoxy Paint Condition Sample Ref Sample Ref Bell Peel Result Bell Peel Result Pull off result Pull off result
Epoxy Basecoat System PU Colour PU System Epoxy Paint Condition Sample Ref Sample Ref Average SD Average SD
Clear Clear Standard Part Cure 4T1 UV Exposed 159.50 9.26 66.67 20.82
Clear Clear Standard Part Cure 4T1 As received 171.50 5.00 54.00 8.94
Clear Clear Standard Full Cure 4T2 UV Exposed 166.73 23.71 43.33 11.55
Clear Clear Standard Full Cure 4T2 As received 176.67 32.93 59.00 14.32
Clear Clear UV Stabilised Part Cure 3T3 UV Exposed 180.00 50.19 43.33 5.77
Clear Clear UV Stabilised Part Cure 3T3 As received 216.67 19.47 57.50 9.87
Clear Clear UV Stabilised Full Cure 3T4 UV Exposed 202.43 9.12 43.33 5.77
Clear Clear UV Stabilised Full Cure 3T4 As received 224.17 11.25 56.67 16.33
Black Clear Standard Part Cure 4T5 UV Exposed 191.00 14.03 66.67 14.43
Black Clear Standard Part Cure 4T5 As received 195.83 17.15 68.33 29.44
Black Clear Standard Full Cure 4T6 UV Exposed 156.33 13.19 70.00 17.32
Black Clear Standard Full Cure 4T6 As received 164.92 26.66 60.00 15.49
Black Clear UV Stabilised Part Cure 3T7 UV Exposed 220.83 7.64 73.33 20.82
Black Clear UV Stabilised Part Cure 3T7 As received 212.50 11.83 63.00 13.96
Black Clear UV Stabilised Full Cure 3T8 UV Exposed 209.17 32.63 70.00 15.28
Black Clear UV Stabilised Full Cure 3T8 As received 224.58 24.26 70.00 17.89
Aluminium Clear Standard Part Cure 4T9 UV Exposed 178.33 12.58 67.22 14.39
Aluminium Clear Standard Part Cure 4T9 As received 197.08 21.99 68.00 13.78
Aluminium Clear Standard Full Cure 4T10 UV Exposed 158.33 2.89 68.33 16.07
Aluminium Clear Standard Full Cure 4T10 As received 170.50 27.05 60.83 17.44
Aluminium Clear UV Stabilised Part Cure 3T11 UV Exposed 187.50 27.04 78.33 20.21
Aluminium Clear UV Stabilised Part Cure 3T11 As received 207.08 14.27 77.50 17.25
Aluminium Clear UV Stabilised Full Cure 3T12 UV Exposed 220.00 9.01 63.33 5.77
Aluminium Clear UV Stabilised Full Cure 3T12 As received 231.67 27.55 69.17 22.45
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Elastomerics-Recent Projects

• Engine Nose Spinners

• 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

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Elastomerics-Recent Projects

• Propeller Coatings

• 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

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Elastomerics-Recent Projects

• 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
• gt1/2 tonne reduction in VOC Emissions

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Elastomerics-Recent Projects

• 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

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Intumescent Coatings

• Increasing Use of Composites Present
• New Challenges for Fire Protection
• Requirements for Both External
• Cabin Interior Systems
• Each Require Differing Approaches

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Intumescent Coatings

• Cabin Interior Systems

• Both Decorative Functional Requirements
• Main Requirements
• Technical Non Burn Coatings
• Low/No Smoke Release
• (FAR 25853 Specification)
• Hardness/Durability
• Decorative Colour Finish Continuity
• Textured Finish

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Intumescent Coatings

• 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

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Intumescent Coatings

• 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)

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Intumescent Coatings

• 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

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Intumescent Coatings

• 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

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Intumescent Coatings

• Control Boxes-recorders

• Test 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

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Intumescent Coatings

• CONTROL BOXES/RECORDERS

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Intumescent Coatings

• Control Boxes-recorders

• Intumescence Values

System 1 System 1 System 2 System 2 System 3 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
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Front View System 1 System 2 System 3
2 Minute Burn
5 Minute Burn
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Side View System 1 System 2 System 3
2 Minute Burn
5 Minute Burn
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Intumescent Coatings

• Control Boxes-recorders

• Report/Comments
• All Three Systems Met Original
• Requirements
• IP 1265 Thermal Intumescent Gave Off
• Slightly More Smoke
• IP 9189 Selected For Use

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In mould primer application
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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.

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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

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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

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Exciting new developments
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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

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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!

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Increased Hardness Resistance Properties

• Requirement for
• Improvements in
• Surface Hardness/
• Erosion Resistance
• Heat Resistance/
• Intumescence/Thermal Barrier
• Chemical Resistance

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Increased Hardness Resistance Properties

• Alternative Solutions
• Alternative Cure
• Methods on Heat
• Sensitive Substrates
• Formulation of Cold/
• Low Temp Cure
• Products With
• Increased Performance

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Environmental/Legislative Issues

• REACH
• SVHCs
• Ongoing Restrictions
• Solvents Directive
• HAPS
• CLP
• GHS

• CrVI Elimination
• CRIII Elimination
• VOC Reduction/
• Elimination

• Example Propeller Manufacturer Discussed
  Earlier
• VOC Reduction of
• gt1/2 Tonne

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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