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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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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
facilities at uk base
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
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

Major Customers/Approvals
product types
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
typically coatings must resist
Typically, Coatings Must Resist:
  • High Heat: >500-600oC
  • High Chemical Attack: Skydrol ;

de icers etc

  • Erosion: Rain & Particle
  • Corrosion
  • Heat & Thermal Conductivity
  • Fuel and Lubricants
initial work
Initial Work
  • Intumescent System for Helicopter

Doors & Hatches

  • Coatings for Automotive Use (Motor

Cycle Fairings; Small Car

Components)

composite airframed vehicles
Composite Airframed Vehicles

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

composite airframed vehicles15
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)

composite airframed vehicles16
Composite Airframed Vehicles

HAL DHRUV Advanced Light Helicopter

elastomeric pu coatings
Elastomeric PU Coatings

Benefits

  • Erosion Resistance
  • Flexibility
  • Exterior Durability

Issues

  • Application
  • System Adhesion

Areas of Use

  • Engine Nose Spinners
  • Propeller Blades
  • Radome Coatings
elastomerics recent projects
Elastomerics-Recent Projects

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

elastomerics recent projects20
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
elastomerics recent projects21
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

elastomerics recent projects22
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

>1/2 tonne reduction in VOC Emissions

elastomerics recent projects23
Elastomerics-Recent Projects

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”

intumescent coatings
Intumescent Coatings
  • Increasing Use of Composites Present

New Challenges for Fire Protection

  • Requirements for Both “External” &

“Cabin Interior” Systems

  • Each Require Differing Approaches
intumescent coatings25
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

intumescent coatings26
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

intumescent coatings27
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)

intumescent coatings28
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

intumescent coatings29
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

intumescent coatings30
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

intumescent coatings31
Intumescent Coatings

CONTROL BOXES/RECORDERS

intumescent coatings32
Intumescent Coatings

Control Boxes-recorders

Intumescence Values

intumescent coatings35
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

in mould primers
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.

in mould primers38
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

in mould primers39
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

electrical conductive coatings
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

bruisable coatings
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!

increased hardness resistance properties
Increased Hardness & Resistance Properties
  • Requirement for

Improvements in:

Surface Hardness/

Erosion Resistance

Heat Resistance/

Intumescence/Thermal Barrier

Chemical Resistance

increased hardness resistance properties44
Increased Hardness & Resistance Properties
  • Alternative Solutions:

Alternative Cure

Methods on Heat

Sensitive Substrates

Formulation of Cold/

Low Temp Cure

Products With

Increased Performance

environmental legislative issues
Environmental/Legislative Issues
  • 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

+44 (0)121 702 2485

Outside UK office hours please use the form at: -

www.indestructible.co.uk/form