2. Engineered Coatings for Composites & Polymers Used in Defence & Aerospace: Now & the Future Hamburg: February Graham Armstrong FIMF Technical Sales Manager

3. Engineered Coatings & Coatings for Engineering

4. Indestructible The Company and Our Products

5. 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

6. 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

7. Major Customers/Approvals
Rolls Royce
Turbomeca
ITP GE
Sikorsky
Meggitt ABS
HAL India
Messier Dowty
Honeywell
Airbus
McDonnell Douglas Boeing
OEM & Overhaul: In House &
Pratt & Whitney (PWA/CPW)
MTU Germany
IAE
Allied Signal
Eurocopter
BAe
Snecma
Goodrich
Hamilton Sundstrand
Agusta-Westland
HAESL/SAESL/TAESL
their Suppliers/Contractors

8. 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

9. Typically, Coatings Must Resist:
High Heat: > oC
High Chemical Attack: Skydrol ;
de icers etc
Erosion: Rain & Particle
Corrosion
Heat & Thermal Conductivity
Fuel and Lubricants

10. Coatings for composites the current status

11. Initial Work Intumescent System for Helicopter Doors & Hatches
Coatings for Automotive Use (Motor
Cycle Fairings; Small Car
Components)

12. Recent Development Projects

13. Composite Airframed Vehicles Elastomeric coatings INTUMESCEnt & thermal barrier coatings

14. 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
Lightweight Spray
Primer-Filler
2K Epoxy “Putty”
(Localised Use)
Low VOC 2K PU
Finishes

15. Composite Airframed Vehicles
HAL DHRUV Advanced Light Helicopter
MPC R3 Primer-
Surfacer on Majority
of Airframe
MPC R3
Lightweight Filler on
Engine Firewall & on
Engine Exhausts
IP6 PU Finish (Matt IRR Camouflage Colours)

16. Composite Airframed Vehicles
HAL DHRUV Advanced Light Helicopter

17. Elastomeric PU Coatings
Benefits
Erosion Resistance
Flexibility
Exterior Durability
Issues
Application
System Adhesion
Areas of Use
Engine Nose Spinners
Propeller Blades
Radome Coatings

18. 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

19. Clear Standard Part Cure 4T1 UV Exposed 159.50 9.26 66.67 20.82
Epoxy Basecoat
System
PU Colour
PU System
Epoxy Paint Condition
Sample Ref
Bell Peel Result
Pull off result
Average SD
Clear
Standard
Part Cure
4T1
UV Exposed
159.50
9.26
66.67
20.82
As received
171.50
5.00
54.00
8.94
Full Cure
4T2
166.73
23.71
43.33
11.55
176.67
32.93
59.00
14.32 UV
Stabilised
3T3
180.00
50.19
5.77
216.67
19.47
57.50
9.87
3T4
202.43
9.12
224.17
11.25
56.67
16.33
Black
4T5
191.00
14.03
14.43
195.83
17.15
68.33
29.44
4T6
156.33
13.19
70.00
17.32
164.92
26.66
60.00
15.49
3T7
220.83
7.64
73.33
212.50
11.83
63.00
13.96
3T8
209.17
32.63
15.28
224.58
24.26
17.89
Aluminium
4T9
178.33
12.58
67.22
14.39
197.08
21.99
68.00
13.78
4T10
158.33
2.89
16.07
170.50
27.05
60.83
17.44
3T11
187.50
27.04
78.33
20.21
207.08
14.27
77.50
17.25
3T12
220.00
9.01
63.33
231.67
27.55
69.17
22.45

20. 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

21. 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

22. 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

23. 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 & Client Electrical
Transparency

24. Intumescent Coatings Increasing Use of Composites Present
New Challenges for Fire Protection
Requirements for Both “External” &
“Cabin Interior” Systems
Each Require Differing Approaches

25. Cabin Interior Systems
Intumescent Coatings
Cabin Interior Systems
Both Decorative & Functional Requirements
Main Requirements:
Technical: Non Burn Coatings
Low/No Smoke Release
(FAR Specification)
Hardness/Durability
Decorative: Colour & Finish Continuity
Textured Finish

26. Cabin Interior Systems
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

27. Control Boxes-recorders
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)

28. Control Boxes-recorders
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: ) IP 1265 Thermal Intumescent
2.) Combination IP1265/IP9189
3.) IP 9189 Full Intumescent
Top Coat: Low VOC 2K Epoxy Low Flame Spread Finish

29. Control Boxes-recorders
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

30. Control Boxes-recorders (to follow set up in BSX 37)
Intumescent Coatings
Control Boxes-recorders
Test Procedure
(to follow set up in BSX 37)
Heat Source: Rothenburger Superfire 2 Torch
Flame Temperature: 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

31. CONTROL BOXES/RECORDERS
Intumescent Coatings
CONTROL BOXES/RECORDERS

32. Control Boxes-recorders
Intumescent Coatings
Control Boxes-recorders
Intumescence Values
System 1
System 2
System 3
2 Min
5Min
Height of Char (mm)
9.46
9.95
9.52
9.55
12.28
11.38
Original FT (µm)
350
334
333
Degree of Intumescence (Ratio)
26.00
27.40
27.50
27.60
35.90
33.20

33. Front View
System 1
System 2
System 3
2 Minute Burn
5 Minute Burn

34. Side View
System 1
System 2
System 3
2 Minute Burn
5 Minute Burn

35. Control Boxes-recorders
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

36. In mould primer application

37. 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.

38. 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

39. 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

40. Exciting new developments

41. 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

42. Bruisable Coatings Damage to Investigation into 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!

43. Increased Hardness & Resistance Properties
Requirement for
Improvements in:
Surface Hardness/
Erosion Resistance
Heat Resistance/
Intumescence/Thermal Barrier
Chemical Resistance

44. Increased Hardness & Resistance Properties
Alternative Solutions:
Alternative Cure
Methods on Heat
Sensitive Substrates
Formulation of Cold/
Low Temp Cure
Products With
Increased Performance

45. 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

46. For more information please contact our technical department
+44 (0)
Outside UK office hours please use the form at: -