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Engineered Coatings for Composites & Polymers Used in Defence & Aerospace: Now & the Future Hamburg: 10-11 February 2010 Graham Armstrong FIMF Technical Sales Manager Engineered Coatings & Coatings for Engineering Indestructible The Company and Our Products

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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 Defence & Aerospace: Now & the Future


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Indestructible Defence & Aerospace: Now & the FutureThe Company and Our Products


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  • Birmingham Based SME; In Existence Since 1978 Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

  • 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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Rolls Royce Defence & Aerospace: Now & the Future

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

Major Customers/Approvals


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Product Types Defence & Aerospace: Now & the Future

  • 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: Defence & Aerospace: Now & the Future

  • High Heat: >500-600oC

  • High Chemical Attack: Skydrol ;

    de icers etc

  • Erosion: Rain & Particle

  • Corrosion

  • Heat & Thermal Conductivity

  • Fuel and Lubricants


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Coatings for composites Defence & Aerospace: Now & the Futurethe current status


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Initial Work Defence & Aerospace: Now & the Future

  • Intumescent System for Helicopter

    Doors & Hatches

  • Coatings for Automotive Use (Motor

    Cycle Fairings; Small Car

    Components)


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Recent Development Projects Defence & Aerospace: Now & the Future


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Composite Defence & Aerospace: Now & the FutureAirframed VehiclesElastomeric coatingsINTUMESCEnt & thermal barrier coatings


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Composite Airframed Vehicles Defence & Aerospace: Now & the Future

HAL DHRUV Advanced Light Helicopter

Low VOC 2K Epoxy

Primer-Surfacer

Low VOC 2K Epoxy

Lightweight Spray

Primer-Filler

2K Epoxy “Putty”

(Localised Use)

Low VOC 2K PU

Finishes

  • Fully Composite

    Airframe

  • Composite Rotor

    Blades

  • Resin Rich/Weak

    Surfaces

    Specifications


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Composite Airframed Vehicles Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

HAL DHRUV Advanced Light Helicopter


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Elastomeric PU Coatings Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

Engine Nose Spinners

Investigative Work

Clear or Pigmented Base Coat

Supply of “User Friendly” 2 Component System

Integration of UV Absorbers

  • Adhesion Failures in Use

  • Causes felt to be:

    Base Coat

    Application

    UV Resistance


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Elastomerics-Recent Projects Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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

    >1/2 tonne reduction in VOC Emissions


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Elastomerics-Recent Projects Defence & Aerospace: Now & the Future

Radome coatings

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

  • Specific Requirements:

    Erosion Resistance

    (Rain & Particle)

    Electrical Transparency

  • Client Issues

    Current Product Exhibits “Reversion”


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Intumescent Coatings Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future

CONTROL BOXES/RECORDERS


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Intumescent Coatings Defence & Aerospace: Now & the Future

Control Boxes-recorders

Intumescence Values


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Intumescent Coatings Defence & Aerospace: Now & the Future

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 Defence & Aerospace: Now & the Future


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In Mould Primers Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future


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Electrical Conductive Coatings Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

  • Requirement for

    Improvements in:

    Surface Hardness/

    Erosion Resistance

    Heat Resistance/

    Intumescence/Thermal Barrier

    Chemical Resistance


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Increased Hardness & Resistance Properties Defence & Aerospace: Now & the Future

  • 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 Defence & Aerospace: Now & the Future

  • REACH

    SVHC’s

    Ongoing Restrictions

  • Solvents Directive

  • HAPS

  • CLP

  • GHS

  • CrVI Elimination

  • CRIII Elimination

  • VOC Reduction/

    Elimination

  • Example: Propeller Manufacturer Discussed Earlier:

    VOC Reduction of

    >1/2 Tonne


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For more information please contact our technical department Defence & Aerospace: Now & the Future

+44 (0)121 702 2485

Outside UK office hours please use the form at: -

www.indestructible.co.uk/form


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