Electrically Conductive Hot Melt Adhesives for Rapid Aerospace Fastener Preparation

The current practice for joining airframe structures together involves a costly and labor intensive process. Fasteners are often conversion-coated, primed, and sealed with an electrically conductive hot melt material. The existing hot melt material provides adequate conductivity, but is expensive, lacks the flexibility needed for long term durability, and takes several minutes to apply to each fastener location. In order to reduce manufacturing costs, a new hot melt material is needed that is less expensive, has a shorter application process, and greater in service durability. To address the need for an improved fastener fill material with the combination of excellent mechanical properties and conductivity, Luna Innovations is developing an electrically conductive hot melt adhesive by combining unique conductive fillers with novel hot melt adhesives. By combining both structural adhesive aspects including optimum adhesion and flexibility, and electrical conductivity, the Luna hot melt will save on materials costs, installation time, repair costs, and overall aircraft cost. BENEFIT: Luna’s innovative solution will save direct and indirect costs while accelerating aircraft production. By reducing the time it takes to install the hot melt adhesive and improving overall field performance and durability, significant benefits will be realized. An extension in service life will translate into savings for both time and labor expenses as well as raw material costs. Example applications can be found in all branches of the military (Air Force, Army, Marines, Navy) on structures (especially organic composites such as aircraft wing lay-ups) and in numerous commercial construction/structural applications where rapid deployment of a conductive hot melt adhesive is beneficial.