Abstract: A conductive sleeved fastener assembly includes an electrically-conductive fastener having a fastener head and a fastener shank extending from the fastener head and an electrically-conductive fastener sleeve receiving the fastener shank of the fastener and a fastener sleeve flange provided on the fastener sleeve and disposed in direct contact with the fastener head of the fastener. A method of preparing a conductive sleeved fastener for use is also disclosed.

Abstract: A repair apparatus for an electrically conductive layer of a composite structure includes a dielectric layer, having a perimeter, secured to the composite structure, a first adhesive layer, and a conductive layer, secured over the dielectric layer and to the composite structure via the first adhesive layer around an entirety of the perimeter of the dielectric layer, the first adhesive layer being scored along a perimeter region thereof to improve a conductive path between the conductive layer and the composite structure.

Abstract: A conductive fastener assembly, system, and method are described. The fastener assembly includes a nut having a counterbore formed therein. The counterbore is formed to maintain a sufficient gap between the nut and the protruding end of a fastener sleeve. The nut with the counterbore improves the conductive fastener system such that the need for a solid copper grid and a cap seal is reduced or eliminated.

Abstract: A conductive fastener assembly, system, and method, wherein the fastener assembly includes a fastener, a fastener sleeve, a nut, and a lubricant coating. The lubricant coating is deposited on a distal portion of a fastener shank and is omitted from the rest of the fastener. To overcome the stresses placed on the fastener sleeve by the insertion of the fastener shank largely devoid of a lubricant coating, the fastener sleeve is reinforced by one or more of an increased thickness, a high-strength alloy, and a soft metal coating.

Abstract: A repair apparatus for an electrically conductive layer of a composite structure includes a dielectric layer, having a perimeter, secured to the composite structure, a first adhesive layer, and a conductive layer, secured over the dielectric layer and to the composite structure via the first adhesive layer around an entirety of the perimeter of the dielectric layer, the first adhesive layer being scored along a perimeter region thereof to improve a conductive path between the conductive layer and the composite structure.

Abstract: A repair apparatus for an electrically conductive layer of a composite structure includes a dielectric layer, having a perimeter, secured to the structure, and a conductive layer, secured over the dielectric layer and to the structure around an entirety of the perimeter of the dielectric layer, the conductive layer being treated along a perimeter region thereof to improve a conductive path between the conductive layer and the structure.

Abstract: A conductive fastener assembly, system, and method are described. The fastener assembly includes a nut having a counterbore formed therein. The counterbore is formed to maintain a sufficient gap between the nut and the protruding end of a fastener sleeve. The nut with the counterbore improves the conductive fastener system such that the need for a solid copper grid and a cap seal is reduced or eliminated.

Abstract: A conductive fastener assembly, system, and method, wherein the fastener assembly includes a fastener, a fastener sleeve, a nut, and a lubricant coating. The lubricant coating is deposited on a distal portion of a fastener shank and is omitted from the rest of the fastener. To overcome the stresses placed on the fastener sleeve by the insertion of the fastener shank largely devoid of a lubricant coating, the fastener sleeve is reinforced by one or more of an increased thickness, a high-strength alloy, and a soft metal coating.

Abstract: The present disclosure describes a conductive fastener assembly, system, and method, wherein the fastener assembly comprises a nut having a counterbore formed therein. The counterbore is formed to maintain a sufficient gap between the nut and the protruding end of a fastener sleeve. The nut with the counterbore improves the conductive fastener system such that the need for a solid copper grid and a cap seal is reduced or eliminated.

Abstract: The present disclosure describes a conductive fastener assembly, system, and method, wherein the fastener assembly comprises a fastener, a fastener sleeve, a nut, and a lubricant coating. The lubricant coating is deposited on a distal portion of a fastener shank and is omitted from the rest of the fastener. To overcome the stresses placed on the fastener sleeve by the insertion of the fastener shank largely devoid of a lubricant coating, the fastener sleeve is reinforced by one or more of an increased thickness, a high-strength alloy, and a soft metal coating.

Abstract: A repair apparatus for an electrically conductive layer of a composite structure includes a dielectric layer, having a perimeter, secured to the structure, and a conductive layer, secured over the dielectric layer and to the structure around an entirety of the perimeter of the dielectric layer, the conductive layer being treated along a perimeter region thereof to improve a conductive path between the conductive layer and the structure.

Abstract: A conductive sleeved fastener assembly includes an electrically-conductive fastener having a fastener head and a fastener shank extending from the fastener head and an electrically-conductive fastener sleeve receiving the fastener shank of the fastener and a fastener sleeve flange provided on the fastener sleeve and disposed in direct contact with the fastener head of the fastener. A method of preparing a conductive sleeved fastener for use is also disclosed.

Abstract: A lightning-protected conductive composite fuel tank includes a conductive material arrayed on an outer surface to at least partially cover a fastener centerline. Through holes extend along the fastener centerline through the conductive material and the underlying fuel tank shell. These through holes are countersunk into the fuel tank shell to a depth such that a fastener in a through hole will avoid electrical continuity or communication with the conductive material on the fuel tank outer surface. The gap in the countersunk through holes, between the fastener heads and the coextensive outer surface of the fuel tank, is filled with a dielectric or nonconductive material.

Abstract: An apparatus comprises a wall, an internal structure, and a fastener. The wall has a conductive surface and a countersunk hole. The countersunk hole passes through the internal structure. The fastener has an interference fit within the countersunk hole.

Abstract: A lightning-protected conductive composite fuel tank includes a conductive material arrayed on an outer surface to at least partially cover a fastener centerline. Through holes extend along the fastener centerline through the conductive material and the underlying fuel tank shell. These through holes are countersunk into the fuel tank shell to a depth such that a fastener in a through hole will avoid electrical continuity or communication with the conductive material on the fuel tank outer surface. The gap in the countersunk through holes, between the fastener heads and the coextensive outer surface of the fuel tank, is filled with a dielectric or nonconductive material.

Abstract: A lightning-protected conductive composite fuel tank includes a conductive material arrayed on an outer surface to at least partially cover a fastener centerline. Through holes extend along the fastener centerline through the conductive material and the underlying fuel tank shell. These through holes are countersunk into the fuel tank shell to a depth such that a fastener in a through hole will avoid electrical continuity or communication with the conductive material on the fuel tank outer surface. The gap in the countersunk through holes, between the fastener heads and the coextensive outer surface of the fuel tank, is filled with a dielectric or nonconductive material.

Abstract: A system and method for preventing sparking or arcing within a fuel tank area is provided. The method includes installing an electrical bond between a fuel access door to a fuel tank skin; isolating the fuel access door and the fuel tank skin; and installing a fuel seal between the inner side of the fuel tank skin and the fuel access door.

Abstract: A method and system of preventing lighting from puncturing composite surfaces is provided. The method includes reconfiguring plies of a composite surface so that a composite conductive ply is located on the outer surface of the composite surface and a non-conductive composite ply is located directly underneath the conductive ply and inserting a flashover point between an outer edge of the conductive ply and a fastener attaching the composite surface to a support structure.

Abstract: An apparatus comprises a wall, an internal structure, and a fastener. The wall has a conductive surface and a countersunk hole. The countersunk hole passes through the internal structure. The fastener has an interference fit within the countersunk hole.

Abstract: A lightning-protected conductive composite fuel tank includes a conductive material arrayed on an outer surface to at least partially cover a fastener centerline. Through holes extend along the fastener centerline through the conductive material and the underlying fuel tank shell. These through holes are countersunk into the fuel tank shell to a depth such that a fastener in a through hole will avoid electrical continuity or communication with the conductive material on the fuel tank outer surface. The gap in the countersunk through holes, between the fastener heads and the coextensive outer surface of the fuel tank, is filled with a dielectric or nonconductive material.