Observations of severe in-flight environments on airplane composite structural components

The development of relatively inexpensive, highly sophisticated avionics systems makes it now possible for general aviation aircraft to fly under more severe weather conditions than formerly. Increased instrument flying increases exposure of aircraft to potentially severe thunderstorm activity such as high rain rates, hail stones, and lightning strikes. In particular, the effects of lightning on aircraft can be catastrophic. Interest in aircraft lightning protection has been stimulated by the introduction of advanced composites as an aircraft structural material. The present investigation has the objective to report experiences with three composite components which have flown in thunderstorms, taking into account three F-106B composite fin caps. The only visible lightning strike damage to a flame sprayed aluminum coated glass/epoxy fin cap was a small area of the aluminum which was burned. Visible lightning strike damage to a Kevlar/epoxy fin cap was limited to the exterior ply of aluminum coated glass fabric. In the case of a graphite/epoxy fin cap, lightning currents could be conducted.