Method for fabrication of integrated lightning strike protection material

A method for fabricating a composite structure having lightning strike protection, the method comprising:

• loading at ambient temperature an integrated lightning strike protection material into an automated contour tape laying machine (CTLM), wherein the integrated lightning strike protection material is optimized for controlled automated placement via the CTLM, the integrated lightning strike protection material comprising:
• a surfacing layer with a fiber reinforcement material layer, the surfacing layer including an organic polymer resin;
• a conductive layer comprising an expanded metal foil encapsulated in the organic polymer resin and having an ability to flex in an x-y plane and in a z plane, the conductive layer adjacent the surfacing layer;
• a tack layer adjacent the conductive layer, the tack layer being compatible with the expanded metal foil and with the CTLM;
• and,
• a carrier layer adjacent the tack layer, and,
• wherein the surfacing, conductive, tack, and carrier layers have parameters optimized for controlled automated placement via the CTLM, the parameters selected from the group consisting of flexibility, tack, lightning strike protection, and environmental performance;
• laying up at ambient temperature the integrated lightning strike protection material directly onto a composite structure or a tool via controlled automated placement with the CTLM;
• and,
• laminating at ambient temperature the integrated lightning strike protection material onto the composite structure to form a composite structure with lightning strike protection, wherein the lightning strike protection material meets electromagnetic effects protection.

A method for fabricating an aircraft composite structure having an integrated lightning strike protection material providing lightning strike protection, the method comprising:

• loading at ambient temperature an integrated lightning strike protection material into an automated contour tape laying machine (CTLM), wherein the integrated lightning strike protection material is optimized for controlled automated placement via the CTLM, the integrated lightning strike protection material comprising:
• a surfacing layer with a fiber reinforcement material layer, the surfacing layer including an organic polymer resin;
• a conductive layer comprising an expanded metal foil encapsulated in the organic polymer resin and having an ability to flex in an x-y plane and in a z plane, the conductive layer adjacent the surfacing layer;
• a tack layer adjacent the conductive layer, the tack layer being compatible with the expanded metal foil and with the CTLM;
• and,
• a carrier layer adjacent the tack layer, and,
• wherein the surfacing, conductive, tack, and carrier layers have parameters optimized for controlled automated placement via the CTLM, the parameters selected from the group consisting of flexibility, tack, lightning strike protection, and environmental performance;
• laying up at ambient temperature the integrated lightning strike protection material directly onto a composite structure or a tool via controlled automated placement with the CTLM;
• and,
• laminating at ambient temperature the integrated lightning strike protection material onto the composite structure to form an aircraft composite structure with lightning strike protection, wherein the lightning strike protection material meets electromagnetic effects protection.