Experimental Studies and Finite Element Modeling Of Lightning Damage to Carbon/Epoxy Laminated and Stitched Composites

Lightning damage resistance of unstitched carbon/epoxy laminates and a Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) panel were characterized by laboratory-scale lightning strike tests and multiphysics-based lightning strike finite element (FE) models. This dissertation combines three related research topics: (1) a three-dimensional (3D) heat transfer problem, (2) lightning damage resistance assessments of carbon/epoxy laminates, and (3) lightning damage resistance of PRSEUS panel. The first project deals with a 3D analytical heat transfer problem as a solid foundation for understanding the steady-state temperature distribution in an anisotropic composite heat spreader. The second project characterizes lightning damage to unprotected carbon/epoxy laminates and laminates with either copper mesh (CM) or pitch carbon fiber paper (PCFP) protection layers subjected to standard impulse current waveforms, consistent with actual lightning waveforms, with 50, 125, and 200 kA nominal peak currents. Multiphysics-based FE models were developed to predict matrix thermal decomposition (a primary form of lightning damage) in unprotected, CM-protected, and PCFP-protected carbon/epoxy laminates. The predicted matrix decomposition domains in the damaged laminates showed good agreement with experimental results available in the literature. Both the CM and the PCFP lightning protection layers successfully mitigated lightning damage development in the underlying composites. The third project includes lightning damage characterization of a PRSEUS panel. Laboratory-scale lightning strike tests with nominal 50, 125, and 200 kA peak currents were performed at the mid-bay, stringer, frame, and frame/stringer intersection locations of the PRSEUS panel. The elliptical regions of intense local damage were elongated along the outermost lamina’s carbon fiber direction, consistent with observations from the unstitched carbon/epoxy laminates. However, the damaged PRSEUS panel exhibited unique damage features due to use of warp-knitted fabrics and through-thickness VectranTM stitches. The polyester threads used to weave the warp-knitted laminates locally confined small-scale fiber damage. This resulted in somewhat periodic and scattered small tufts of carbon fibers near the lightning attachments. Through-thickness VectranTM stitches also confined intense local damage development at the stringer and frame locations. The polyester warp-knit fabric skins and through-thickness VectranTMstitches have a significant beneficial effect on lightning damage development on a PRSEUS panel

How to protect a wind turbine from lightning

Techniques for reducing the chances of lightning damage to wind turbines are discussed. The methods of providing a ground for a lightning strike are discussed. Then details are given on ways to protect electronic systems, generating and power equipment, blades, and mechanical components from direct and nearby lightning strikes

Developing Test Methods for Compression after Lightning Strikes

Research into residual strength after lightning strike is increasing within the literature. However, standard test methods for measuring residual compressive strength after lightning strikes do not exist. For the first time, a systematic experimental study is undertaken to evaluate modifications necessary to standard Compression After Impact (CAI) specimen geometry and test jig design to induce specimen failure at the lightning damage region. Four laboratory generated lightning strike currents with peak amplitudes ranging from 25 to 100kA have been studied. Test set-up modifications were made considering the scale of the lightning damage and its potential proximity to specimen edges. Specimen geometry and anti-buckling guides were adjusted for each peak current to induce specimen failure at the lightning damage. The Compression After Lightning (CAL) strength was 28% lower than the pristine CAI strength even at a relatively low peak current of 25 kA. This study shows that the standard CAI test setup has the potential for CAL application, however, careful modifications are required depending on the peak amplitude of the applied lightning current waveform

Electrical Characterizations of Lightning Strike Protection Techniques for Composite Materials

The growing application of composite materials in commercial aircraft manufacturing has significantly increased the risk of aircraft damage from lightning strikes. Composite aircraft designs require new mitigation strategies and engineering practices to maintain the same level of safety and protection as achieved by conductive aluminum skinned aircraft. Researchers working under the NASA Aviation Safety Program s Integrated Vehicle Health Management (IVHM) Project are investigating lightning damage on composite materials to support the development of new mitigation, diagnosis & prognosis techniques to overcome the increased challenges associated with lightning protection on composite aircraft. This paper provides an overview of the electrical characterizations being performed to support IVHM lightning damage diagnosis research on composite materials at the NASA Langley Research Center

Experimental and Modelling of Lightning Damage to Carbon Fibre-Reinforced Composites Under Swept Stroke

Lightning swept stroke creates multiple lightning attachments along an aircraft in flight. This introduces distinct structural damage compared to that from a single-point lightning current injection test in laboratory. This study presents both experimental and numerical studies on lightning damage in carbon fibre-reinforced polymer (CFRP) composites under swept stroke. Coupled electrical–thermal finite element (FE) models were proposed to predict lightning damage to CFRP composites under single-point current injection and swept stroke, respectively. A lightning swept stroke testing method was proposed by embedding a copper wire inside the composites to simulate multiple lightning attachments on the composites. The FE-predicted damage from single-point current injection and swept stroke were comparable to those obtained from the experiments with a deviation less than 23%, demonstrating the effectiveness of the proposed FE model. Finally, the FE model was further utilised to gain insights into the failure mechanism of CFRP composites under swept stroke associated with different skip distances and peak currents. This paper provides an experimental method and a FE model for obtaining the LS damage of CFRP composite by swept stroke

Simulated lightning test shuttle .03 scale model

Lightning Attach Point tests were conducted for the space shuttle launch configuration (Orbiter, External Tank and Solid Rocket Boosters). A series of 250 long spark tests (15 to 20 foot sparks) determined that the orbiter may be struck on the nose, windshield brow, tail and wingtips during launch but not on the main engine nozzles which have been shown to be vulnerable to lightning damage. The orbiter main engine and SRB exhaust plumes were simulated electrically with physical models coated with graded resistance paints. The tests showed that the exhaust plumes from the SRB provide additional protection for the main engine nozzles. However, the tests showed that the Orbiter Thermal Protection System (TPS), which has also been shown to be vulnerable to lightning damage, may be struck during launch. Therefore further work is indicated in the areas of swept stroke studies on the model and on TPS panels. Further attach point testing is also indicated on the free-flying orbiter. Photographs of the test setup are shown

Lightning damage stimulates beetle activity in a tropical forest

Disturbance alters the structure of ecological communities. Localized disturbances in tropical rainforests often create canopy gaps - patches of forest where large trees have fallen or are defoliated. Lightning is a major cause of large-tree mortality, and consequently gaps, in tropical forests. Lightning-caused gaps consist of abundant dead standing wood which likely is a predictable resource for saproxylic arthropods, specifically wood-boring beetles (Coleoptera). The goal of this study was to provide a preliminary evaluation of the beetles that are attracted to lightning-damaged trees in a tropical forest. We placed flight intercept traps in the subcanopy of 8 trees (4 struck trees and 4 unaffected trees of the same size and species) on Barro Colorado Island, Panama in 2018. Collected beetles were counted and identified to subfamily. Abundance analyses focused on Platypodinae (pinhole borers) and Scolytinae (bark beetles), both of which were significantly more abundant near struck trees vs. unaffected trees. These results suggest that the dead wood of trees struck by lightning is an identifiable resource for saproxylic beetles. Ongoing research will examine differences in beetle communities associated with treefall gaps and lightning gaps. Ultimately, this research will clarify the relevance of lightning to the maintenance of beetle diversity in tropical forests.https://ir.library.louisville.edu/uars/1024/thumbnail.jp

In-flight measurements of energetic radiation from lightning and thunderclouds

In the certification procedure aircraft builders carry out so-called icing tests flights, where the zero degree Celsius altitude is deliberately sought and crossed in or under thunderstorms. Airbus also used these flights to test ILDAS, a system aimed to determine lightning severity and attachment points during flight from high speed data on the electric and magnetic field at the aircraft surface. We used this unique opportunity to enhance the ILDAS systems with two x-ray detectors coupled to high speed data recorders in an attempt to determine the x-rays produced by lightning in-situ, with synchronous determination of the lightning current distribution and electric field at the aircraft. Such data are of interest in a study of lightning physics. In addition, the data may provide clues to the x-ray dose for personnel and equipment during flights. The icing campaign ran in April 2014; in six flights we collected data of 61 lightning strikes on an Airbus test aircraft. In this communication we briefly describe ILDAS and present selected results on three strikes, two aircraft initiated and one intercepted. Most of the x-rays have been observed synchronous with initiating negative leader steps, and as bursts immediately preceding the current of the recoil process. Those processes include the return stroke. The bursts last one to four micro-second and attain x-ray energies up to 10 MeV. Intensity and spectral distribution of the x-rays and the association with the current distribution are discussed. ILDAS also continuously records x-rays at low resolution in time and amplitude.Comment: 28 pages, 9 figure

Development of Prototype Low-cost and High-strength Fault Current Interrupting Arcing Horns for 77 kV Overhead Transmission Lines

Fault Current Interrupting Arcing Horns (FCIAH) are newly designed arcing horns installed on transmis-sion line towers as a countermeasure against lightning damage that greatly contribute to reducing power interruption by interrupting fault current independently within an AC cycle. This paper describes the de-velopment of two new prototype FCIAH for further cost reduction and strength enhancement, using computational fluid dynamics and short-circuit tests