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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.

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Presentation on theme: "Engineered Coatings for Composites & Polymers Used in Defence & Aerospace: Now & the Future Hamburg: 10-11 February 2010 Graham Armstrong FIMF Technical."— Presentation transcript:

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2 Engineered Coatings for Composites & Polymers Used in Defence & Aerospace: Now & the Future Hamburg: February 2010 Graham Armstrong FIMF Technical Sales Manager

3 Engineered Coatings & Coatings for Engineering

4 Indestructible The Company and Our Products

5 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 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

6 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

7 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

8 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

9 Typically, Coatings Must Resist: High Heat: > o C High Chemical Attack: Skydrol ; de icers etc Erosion: Rain & Particle Corrosion Heat & Thermal Conductivity Fuel and Lubricants

10 COATINGS FOR COMPOSITES THE CURRENT STATUS

11 Initial Work Intumescent System for Helicopter Doors & Hatches Coatings for Automotive Use (Motor Cycle Fairings; Small Car Components)

12 RECENT DEVELOPMENT PROJECTS

13 COMPOSITE AIRFRAMED VEHICLES ELASTOMERIC COATINGS INTUMESCENT & THERMAL BARRIER COATINGS

14 Composite Airframed Vehicles Fully Composite Airframe Composite Rotor Blades Resin Rich/Weak Surfaces Specifications 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

15 Composite Airframed Vehicles HAL DHRUV ADVANCED LIGHT HELICOPTER MPC R3 Primer- Surfacer on Majority of Airframe MPC R3 Lightweight Filler on Engine Firewall & on Engine Exhausts IP6 PU Finish (Matt IRR Camouflage Colours)

16 Composite Airframed Vehicles HAL DHRUV ADVANCED LIGHT HELICOPTER

17 Elastomeric PU Coatings Benefits Erosion Resistance Flexibility Exterior Durability Issues Application System Adhesion Areas of Use Engine Nose Spinners Propeller Blades Radome Coatings

18 Elastomerics-Recent Projects Adhesion Failures in Use Causes felt to be: Base Coat Application UV Resistance ENGINE NOSE SPINNERS Investigative Work Clear or Pigmented Base Coat Supply of “User Friendly” 2 Component System Integration of UV Absorbers

19 Epoxy Basecoat System PU ColourPU System Epoxy Paint Condition Sample Ref Bell Peel ResultPull off result AverageSDAverageSD Clear Standard Part Cure4T1UV Exposed As received Full Cure4T2UV Exposed As received UV Stabilised Part Cure3T3UV Exposed As received Full Cure3T4UV Exposed As received BlackClear Standard Part Cure4T5UV Exposed As received Full Cure4T6UV Exposed As received UV Stabilised Part Cure3T7UV Exposed As received Full Cure3T8UV Exposed As received AluminiumClear Standard Part Cure4T9UV Exposed As received Full Cure4T10UV Exposed As received UV Stabilised Part Cure3T11UV Exposed As received Full Cure3T12UV Exposed As received

20 Elastomerics-Recent Projects 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 ENGINE NOSE SPINNERS

21 Elastomerics-Recent Projects 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 PROPELLER COATINGS

22 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

23 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 & Client Electrical Transparency

24 Intumescent Coatings Increasing Use of Composites Present New Challenges for Fire Protection Requirements for Both “External” & “Cabin Interior” Systems Each Require Differing Approaches

25 Intumescent Coatings CABIN INTERIOR SYSTEMS Both Decorative & Functional Requirements Main Requirements: Technical:Non Burn Coatings Low/No Smoke Release (FAR Specification) Hardness/Durability Decorative:Colour & Finish Continuity Textured Finish

26 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

27 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 350 o C (662 o F)

28 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/IP ) IP 9189 Full Intumescent Top Coat: Low VOC 2K Epoxy Low Flame Spread Finish

29 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 80 o C (176 o F) All Panels Allowed 7 days Stabilisation Before Burn Test

30 Intumescent Coatings CONTROL BOXES-RECORDERS Test Procedure (to follow set up in BSX 37) Heat Source: Rothenburger Superfire 2 Torch Flame Temperature:1060 o C (1940 o F) 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

31 Intumescent Coatings CONTROL BOXES/RECORDERS

32 Intumescent Coatings CONTROL BOXES-RECORDERS Intumescence Values System 1System 2System 3 2 Min5Min2 Min5Min2 Min5Min Height of Char (mm) Original FT (µm) Degree of Intumescence (Ratio)

33 Front ViewSystem 1System 2System 3 2 Minute Burn 5 Minute Burn

34 Side ViewSystem 1System 2System 3 2 Minute Burn 5 Minute Burn

35 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

36 IN MOULD PRIMER APPLICATION

37 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.

38 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

39 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

40 EXCITING NEW DEVELOPMENTS

41 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

42 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!

43 Increased Hardness & Resistance Properties Requirement for Improvements in: Surface Hardness/ Erosion Resistance Heat Resistance/ Intumescence/Thermal Barrier Chemical Resistance

44 Increased Hardness & Resistance Properties Alternative Solutions: Alternative Cure Methods on Heat Sensitive Substrates Formulation of Cold/ Low Temp Cure Products With Increased Performance

45 Environmental/Legislative Issues REACH SVHC’s Ongoing Restrictions Solvents Directive HAPS CLP GHS Cr VI Elimination CR III Elimination VOC Reduction/ Elimination Example: Propeller Manufacturer Discussed Earlier: VOC Reduction of >1/2 Tonne

46 For more information please contact our technical department +44 (0) Outside UK office hours please use the form at: -


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