Cost-effective, Scalable and Electrically Conductive Spray Coatings for Lightning Strike

Atmospheric lightning discharge can be triggered during fly-outs and reflect decrement to missile reliability. Coatings and other lightweight mateials for lightning protection represent a potentially low-cost method to mitigate this liability. Focusing on SM-3 Block IIA missile interceptor that has both non-metallic structures and metal alloy components, it is imperative to protect it from lightning strike protection (LSP). Recent aeronautical and aerospace structures are manufactured more carbon and glass fiber reinforced polymer (CFRP and GFRP) laminated composites. The metal alloy protect SM-3 missiles and or aircraft from a lightning strike by distributing electrical current over their surfaces. However, aerospace composite materials are vulnerable to lightning strikes due to their low electrical conductivity and low heat resistance. Because of this, a lightning strike can damage CFRP structure catastrophically. Most common LSP technology, regardless of underlying structure materials (i.e. metal alloys or composites) is expanded metal foils/films applied to the top of aircraftÆs outer mold line (OML). This technology possesses disadvantages such as increased weight, galvanic corrosion, expensive integration and repair costs. Texas Biochemicals Inc. recently developed a novel room temperature (RT) spray coating technology for the SM-3 Block IIA missile interceptor. The innovative coating technology provide lightning strike and space environment protection of the missile interceptor; shielding against natural and made radiation, thermal and debris protection of the missile interceptor skin; and ability to survive extreme launch conditions during silo egress. In Phase I, Texas Biochemicals Inc., will advance the novel RT spray coat manufacturing technology for large-scale production, making the production rate faster, environmentally benign and cost effective. Texas Biochemicals Inc. easy to apply RT spray coatings show 3-D conductive network due to its self-assembling property, that makes it superior compared to its counterparts, i.e., carbon/metal nano-filler based LSP technologies that are expensive, difficult to apply in real situations. Collaboration with a prime contractor is established to evaluate representative samples and provide technical guidance. Their inputs described under Phase I tasks and their letters of support demonstrate intentions to become a commercialization partner leading to near term technology utilization potential. Approved for Public Release | 24-MDA-11906 (16 Sep 24)