Abstract
Manufacturing of Carbon Fiber Reinforced Plastics (CFRPs) using additive manufacturing (AM), or 3D printing, has gained popularity in recent years. It is believed that the AM industry has the potential to manufacture CFRP parts in a faster, easier and more economical way. Lightning strike damage to CFRP parts is not rare; therefore, additional lightning strike protection (LSP) technologies are applied on top of CFRP structures. However, there is no report of manufacturing lightning strike protection (LSP) technologies using the AM process. In the present work, the authors applied an electrically conductive layer via additive manufacturing. The material of the electrically conductive layer was a Polyaniline (PANI)-filled thermoset composite. This layer of PANI was deposited on top of the CFRP panels. The PANI-coated CFRP panels were tested against a simulated lightning strike made of a continuous waveform with component A (100 kA), component B (2 kA) and component C (470 A). The highly conductive PANI-layer worked as a capable Faraday cage to safely dissipate the lightning current. In PANI-based LSP, direct contact between PANI chains dominated the conduction behavior, which proved to be a highly efficient way to reduce resistive heating from the incident current. However, poor adhesion between the printed layer and the substrate structure needs to be improved in the future. The results from the thermal camera and the high-speed camera images showed an effective current dissipation through the printed layers. Non-destructive ultrasonic imaging was done to confirm the direct lightning damages to samples. The present work shows that a non-metallic conductive layer can be applied as an LSP of CFRP structures via an additive manufacturing technique.
