Transcript Coatings For Composites & Polymers

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
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
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
Pratt & Whitney (PWA/CPW)
MTU Germany
IAE
Allied Signal
Eurocopter
BAe
Snecma
Goodrich
Hamilton Sundstrand
Agusta-Westland
HAESL/SAESL/TAESL
OEM & Overhaul: In House & their Suppliers/Contractors
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:
High Heat: >500-600oC
High Chemical Attack: Skydrol ;
de icers etc
Erosion: Rain & Particle
Corrosion
Heat & Thermal Conductivity
Fuel and Lubricants
COATINGS FOR COMPOSITES
THE CURRENT STATUS
Initial Work
Intumescent System for Helicopter
Doors & Hatches
Coatings for Automotive Use (Motor
Cycle Fairings; Small Car
Components)
RECENT DEVELOPMENT
PROJECTS
COMPOSITE AIRFRAMED VEHICLES
ELASTOMERIC COATINGS
INTUMESCENT & THERMAL BARRIER
COATINGS
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
Composite Airframed
Vehicles
HAL DHRUV ADVANCED LIGHT
HELICOPTER
MPC 50015-R3 PrimerSurfacer on Majority
of Airframe
MPC 50019-R3
Lightweight Filler on
Engine Firewall & on
Engine Exhausts
IP6 PU Finish (Matt IRR Camouflage Colours)
Composite Airframed
Vehicles
HAL DHRUV ADVANCED LIGHT
HELICOPTER
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
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
Epoxy Basecoat
System
PU Colour
PU System
Part Cure
Standard
Clear
Clear
Full Cure
Part Cure
UV
Stabilised
Full Cure
Part Cure
Standard
Black
Clear
Full Cure
Part Cure
UV
Stabilised
Full Cure
Part Cure
Standard
Aluminium
Clear
Full Cure
Part Cure
UV
Stabilised
Bell Peel Result
Epoxy Paint
Condition
Full Cure
Sample Ref
4T1
4T2
3T3
3T4
4T5
4T6
3T7
3T8
4T9
4T10
3T11
3T12
Pull off result
Average
SD
Average
SD
UV Exposed
159.50
9.26
66.67
20.82
As received
171.50
5.00
54.00
8.94
UV Exposed
166.73
23.71
43.33
11.55
As received
176.67
32.93
59.00
14.32
UV Exposed
180.00
50.19
43.33
5.77
As received
216.67
19.47
57.50
9.87
UV Exposed
202.43
9.12
43.33
5.77
As received
224.17
11.25
56.67
16.33
UV Exposed
191.00
14.03
66.67
14.43
As received
195.83
17.15
68.33
29.44
UV Exposed
156.33
13.19
70.00
17.32
As received
164.92
26.66
60.00
15.49
UV Exposed
220.83
7.64
73.33
20.82
As received
212.50
11.83
63.00
13.96
UV Exposed
209.17
32.63
70.00
15.28
As received
224.58
24.26
70.00
17.89
UV Exposed
178.33
12.58
67.22
14.39
As received
197.08
21.99
68.00
13.78
UV Exposed
158.33
2.89
68.33
16.07
As received
170.50
27.05
60.83
17.44
UV Exposed
187.50
27.04
78.33
20.21
As received
207.08
14.27
77.50
17.25
UV Exposed
220.00
9.01
63.33
5.77
As received
231.67
27.55
69.17
22.45
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 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 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 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
Intumescent Coatings
Increasing Use of Composites Present
New Challenges for Fire Protection
Requirements for Both “External” &
“Cabin Interior” Systems
Each Require Differing Approaches
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 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 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 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 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 Coatings
CONTROL BOXES-RECORDERS
Test Procedure
(to follow set up in BSX 37)
Heat Source:
Flame Temperature:
Rothenburger Superfire 2 Torch
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 Coatings
CONTROL BOXES/RECORDERS
Temperature/Time Comparion
Reverse of Panel
1200
1100
Temperature °C
1000
900
Purple:
Black:
Red:
Yellow:
Grey:
800
700
600
Burner Temperature
Uncoated Panel
System 1
System 2
System 3
500
400
300
200
100
0
0
60
120
180
Time (secs)
240
300
Intumescent Coatings
CONTROL BOXES-RECORDERS
Intumescence Values
System 1
System 2
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
26.00
27.40
27.50
27.60
35.90
33.20
Degree of
Intumescence (Ratio)
Front View
2 Minute Burn
5 Minute Burn
System 1
System 2
System 3
Side View
2 Minute Burn
5 Minute Burn
System 1
System 2
System 3
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 PRIMER
APPLICATION
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 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 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
EXCITING NEW
DEVELOPMENTS
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
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
Requirement for
Improvements in:
Surface Hardness/
Erosion Resistance
Heat Resistance/
Intumescence/Thermal
Barrier
Chemical Resistance
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
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
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