Abstract: An integral lightning protection system and method for its use with an aircraft graphite epoxy structure. If a repair is to be made to an aircraft composite structure, the hole to be repaired is first cleared of broken composite material and replaced with a bonded adhesive patch. Over the patch and conformal to the surface of the aircraft composite structure, a dielectric layer is placed, and over the dielectric layer, at least one metal-plated graphite fiber fabric ply is placed. Where fasteners are inserted through an aircraft composite panel, the heads of the fasteners are left flush with the outer surface of the composite material, and the composite material and fastener heads are adhesively covered by a dielectric cover. Thereafter, at least one metal-plated graphite fiber fabric ply is placed over the dielectric layer. Subsequently, either structure may be given a primer and paint coating.

Abstract: Fastener, e.g., stud, installation in a composite panel, such as a graphite epoxy structure having a longitudinal electrical conductivity substantially greater than the transverse electrical conductivity, is achieved in a manner providing increased conductivity between fastener assembly and the panel to which it is attached. Through panel countersink and fastener configurations, e.g., by use of frustro conical countersink to spherical fastener surface configurations, increased electrical contact is made to conductive fibers in the composite material which run at right angles to the central axis of the fastener.

Abstract: Method and structures for enhancing the conductivity of graphite composite materials for lightning protection and prevention of attachment of lightning to fasteners. The integral lightning protection for composite aircraft skins, including skins with fasteners penetrating into fuel tanks, utilizes metal coated or plated graphite fibers which are woven into the outer layer of tape or fabric of the structural component requiring protection.

Abstract: Method and structures for enhancing the conductivity of graphite composite materials for lightning protection and prevention of attachment of lightning to fasteners. The integral lightning protection system for composite aircraft skins, including skins with fasteners penetrating into fuel tanks, utilizes nickel-plated graphite fibers (24) which are woven into the outer layer of fabric of the structural component (10) requiring protection.

Abstract: A lightning protection system for advanced composite aircraft structures consisting of a sandwich structure including two layers of aluminum foil separated by a layer of dielectric material. The sandwich structure is applied to the surface of the composite aircraft structure desired to be protected from lightning strike damage thereby confining damage to the sandwich structure which can be removed and replaced.