Abstract: Provided is a protection film including a plurality of layers, including a first carrier layer having a plurality of electrically conductive fibers; a metal layer; and a second carrier layer having a plurality of electrically conductive fibers. Each of the first and second carrier layers has a void volume at least partially filled with a hardenable composition. Also provided is a protection film including a first metal layer, a carrier layer, and a second metal layer, in which the carrier layer is at least partially filled with a hardenable composition. These films can provide lightning strike protection with suitable tensile, rigidity and tack properties for automatic tape layup and automatic fiber placement applications.

Abstract: A method of making an electrically-conductive film is provided. The method includes providing a release layer, optionally having a topologically structured surface, and depositing at least one electrically-conductive layer on the release layer whereby the at least one electrically-conductive layer has an outer surface that substantially replicates the topologically structured surface. The electrically-conductive layer can be peeled away from the release layer to obtain the electrically-conductive film. Such electrically-conductive films can be useful in lightning strike applications.

Abstract: Various embodiments disclosed related to sealant tape. The sealant tape can include a cured product of a sealant composition including a curable liquid that includes a polysulfide, a polythioether, a copolymer thereof, or a combination thereof. The sealant composition also includes a curing agent for curing the curable liquid. Various embodiments provide cured products of the sealant composition, sealant tapes including the cured product, and sealant tapes including any suitable material with an adhesive pattern thereon.

Abstract: Methods for making structural shims (220) for the mating assembly of parts, such as for installation between a skin (212) and substructure (214) of an aircraft. The methods include the steps of disposing a hardenable composition (216) into a gap between the first (212) and second parts (214), hardening the hardenable composition to provide a shim pattern (218) that is dimensionally stable, and removing the shim pattern from the gap without damage. The shim pattern can be used to provide a digital model thereof, which can in turn be used to fabricate the structural shim (220).

Abstract: An electroplated article is provided comprising a polymeric substrate bearing an electroplated metal layer comprising copper and tin in an atomic ratio of less than 96:4, in some embodiments less than 87:13 and in some embodiments less than 82:18; wherein the atomic ratio of copper to tin is greater than 55:45, and wherein the electroplated metal layer comprises at least 3.5 weight % tin. The electroplated metal layer comprises an alloy having a melting point of less than 1050° C. and in some cases less than 800° C. The electroplated metal layer has a Young's Modulus of less than 15.0 GPa, in some embodiments less than 13.0 GPa, and in some less than 10.0 GPa. In addition, an electroplating solution is provided comprising Cu(II) ions, Sn (II) ions, Zn(II) ions, 1-methionine, and no cyanide anion.

Abstract: Fiber-reinforced composites is provided. The composites include a plurality of prepreg layers, each comprising a polymeric resin and a plurality of fibers disposed therein; and at least one electrically-conductive layer at least partially embedded in the plurality of prepreg layers. These fiber-reinforced composites can save weight relative to externally provided wires and can be provided in forms suitable for use in automated fiber placement and automated tape layup machines. Advantageous applications include uses in lightning strike protection, energy storage, signal transmission, and power distribution.

Abstract: Lightning strike protection films, along with related assemblies and methods, are provided. These films include an electrically-conductive layer having a plurality of perforations arranged in a hexagonal lattice pattern, wherein the perforations are generally hexagonal. Advantageously, conductive films based on hexagonal perforations can provide greater protection than circular holes for the equivalent weight conductor, thus providing superior lightning strike protection for a given weight.

Abstract: A plated article is provided comprising a) a polymeric substrate bearing b) a tie/seed layer in direct contact with the polymeric substrate and c) a plated metal layer, wherein the tie/seed layer has a thickness of less than 0.95 ?m, and wherein the tie/seed layer comprises two or more layers of tin alternating with two or more layers of copper, and in some embodiments up to ten or more layers of tin alternating with ten or more layers of copper. In some embodiments, the tie/seed layer includes a layer of tin in direct contact with the polymeric substrate. Typically, the layers of tin and copper comprising the tie/seed layer are sputter coated layers. In some embodiments, the plated metal layer comprises an alloy of copper and tin. In some embodiments, the plated metal layer comprises layers comprised of tin alternating with layers comprised of copper.

Abstract: Provided is a protection film including a plurality of layers, including a first carrier layer having a plurality of electrically conductive fibers; a metal layer; and a second carrier layer having a plurality of electrically conductive fibers. Each of the first and second carrier layers has a void volume at least partially filled with a hardenable composition. Also provided is a protection film including a first metal layer, a carrier layer, and a second metal layer, in which the carrier layer is at least partially filled with a hardenable composition. These films can provide lightning strike protection with suitable tensile, rigidity and tack properties for automatic tape layup and automatic fiber placement applications.

Abstract: A plated article is provided comprising a) a polymeric substrate bearing b) a tie/seed layer in direct contact with the polymeric substrate and c) a plated metal layer, wherein the tie/seed layer has a thickness of less than 0.95 ?m, and wherein the tie/seed layer comprises two or more layers of tin alternating with two or more layers of copper, and in some embodiments up to ten or more layers of tin alternating with ten or more layers of copper. In some embodiments, the tie/seed layer includes a layer of tin in direct contact with the polymeric substrate. Typically, the layers of tin and copper comprising the tie/seed layer are sputter coated layers. In some embodiments, the plated metal layer comprises an alloy of copper and tin. In some embodiments, the plated metal layer comprises layers comprised of tin alternating with layers comprised of copper.

Abstract: Provided are articles, along with related methods, capable of providing an effective adhesive bond to a substrate containing polyetherketoneketone. The multilayered article includes a substrate comprising polyetherketoneketone, an adhesion promoter disposed on the substrate, the adhesion promoter comprising at least one of organotitanate, polyamide, surface-treated nanosilica, ammosilane or epoxy silane, and an adhesive bonded to the adhesion promoter. The adhesive contains at least one of an acrylic polymer, a polysulfide, a polythioether, an epoxy resin, or a silicone resin.

Abstract: A method of making an electrically-conductive film is provided. The method includes providing a release layer, optionally having a topologically structured surface, and depositing at least one electrically-conductive layer on the release layer whereby the at least one electrically-conductive layer has an outer surface that substantially replicates the topologically structured surface. The electrically-conductive layer can be peeled away from the release layer to obtain the electrically-conductive film. Such electrically-conductive films can be useful in lightning strike applications.

Abstract: A lightning protective seal cap comprising a seal cap that defines an interior, and a quantity of an uncured sealant that is curable by the application of actinic radiation so as to bind the seal cap to a fastener. The interior of the seal cap contains the quantity of uncured sealant, the seal cap is positionable over the fastener such that at least a portion of the fastener resides in the interior of the seal cap, and when the seal cap is in position over the fastener, the sealant containing seal cap prevents electrical arcing to the fastener from a lightning strike.

Abstract: A lightning protective seal cap comprising a seal cap that defines an interior, and a quantity of an uncured sealant that is curable by the application of actinic radiation so as to bind the seal cap to a fastener. The interior of the seal cap contains the quantity of uncured sealant, the seal cap is positionable over the fastener such that at least a portion of the fastener resides in the interior of the seal cap, and when the seal cap is in position over the fastener, the sealant containing seal cap prevents electrical arcing to the fastener from a lightning strike.

Abstract: The present disclosure provides methods and articles useful in sealing fasteners, including seal caps and methods of their use, and in particular light weight seal caps having higher dielectric breakdown strength, lower weight, and/or lower wall thickness. In some embodiments, the seal caps according to the present invention are made of a material having a dielectric breakdown strength of greater than 1.0 kV/mm, in some embodiments greater than 15.0 kV/mm, and in some embodiments greater than 50.0 kV/mm. In some embodiments, the seal caps according to the present invention are thin-walled, having an average wall thickness of less than 1.5 mm and in some embodiments less than less than 0.5 mm. In some embodiments, the seal cap comprises a polyurethane polymer, a polythioether polymer, a polysulfide polymer, a fluorinated thermoplastic polymer, a THV polymer, a fluorinated thermoset polymer, an engineering thermoplastic, and/or a PEEK polymer.

Abstract: The present disclosure provides methods and articles useful in sealing fasteners, including seal caps and methods of their use, and in particular light weight seal caps having higher dielectric breakdown strength, lower weight, and/or lower wall thickness. In some embodiments, the seal caps according to the present invention are made of a material having a dielectric breakdown strength of greater than 1.0 kV/mm, in some embodiments greater than 15.0 kV/mm, and in some embodiments greater than 50.0 kV/mm. In some embodiments, the seal caps according to the present invention are thin-walled, having an average wall thickness of less than 1.5 mm and in some embodiments less than less than 0.5 mm. In some embodiments, the seal cap comprises a polyurethane polymer, a polythioether polymer, a polysulfide polymer, a fluorinated thermoplastic polymer, a THV polymer, a fluorinated thermoset polymer, an engineering thermoplastic, and/or a PEEK polymer.

Abstract: Methods of using and repairing seal caps as well as constructions comprising seal caps, including in some embodiments seal caps which may be useful in sealing fasteners that protrude into fuel storage cells in aircraft. In some embodiments, methods include the use of optically translucent seal cap and application of a second quantity of sealant to fill voids observed within the interior of the seal cap after cure of a first quantity of sealant.

Abstract: A unitary expanded metal mesh is provided having a down-roll direction, the mesh comprising: a) linear strands that are substantially parallel to the down-roll direction; and b) cross strands which meet the linear strands at nodes. Composites including the unitary expanded metal mesh of the present disclosure and a polymeric matrix are also provided. The unitary expanded metal mesh and composites may be provided as roll goods having, in some embodiments, uninterrupted linear down-roll metal strands for unlimited length. Methods of making the unitary expanded metal mesh of the present disclosure are provided.

Abstract: A method is provided for making structured hybrid adhesive articles such as lightning strike protection sheets. In the embodiment for making lightning strike protection sheets, the method comprises the steps of: a) providing an adhesive article comprising: i) a base resin comprising an epoxy resin, ii) a first epoxy curative, and iii) a second epoxy curative; b) reacting the base resin with the first epoxy curative such that the first epoxy curative is substantially reacted with epoxy resin in the article and the second epoxy curative is substantially unreacted in the article; c) embossing the adhesive article with a relief pattern; d) depositing an electrically-conductive layer onto at least a portion of the embossed surface; and e) curing the adhesive article such that the second epoxy curative is substantially reacted with epoxy in the article. In some embodiments, the method additionally comprises a step of embedding a scrim in the adhesive.

Abstract: Fiber reinforced resin matrix composite laminates are provided comprising: at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising: at least one barrier layer; and at least one cured adhesive layer derived from high temperature cure adhesive. In some embodiments, barrier layer(s) may be substantially impermeable to organic solvents, water, and/or gasses. In another aspect, fiber reinforced resin matrix composite laminates are provided comprising: a) at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and b) a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising: at least one barrier layer; and at least one electrically conductive layer. In another aspect, a surfacing construction is provided comprising a barrier layer and a curable adhesive layer.