A comprehensive analysis of electric, thermal, and structural effects of lightning strikes on CFRP composites and protective strategies

This study examines the influence of lightning strike protection (LSP) systems and lightning parameters on thermal damage and mechanical response behavior of carbon fiber-reinforced polymer (CFRP) composites. A coupled electric-thermal-structural model in COMSOL is employed to analyze the evolution of coupled electrical, thermal, and stress distribution in CFRP composites with two types of LSP systems: copper mesh (CM) and graphene-fuzzy fiber (GF). Although CM system can effectively mitigate matrix decomposition, its high density poses a drawback. Conversely, incorporating a GF layer in CFRP reduces the area and thickness of thermal damage, accompanied by minimal stress in the underlying composite. To further enhance the mitigation of thermal damage and stress, an insulated layer is integrated between the LSP layer and the composite (CM/E/CFRP and GF/E/CFRP). The study also explores how lightning parameters influence the progression of thermal damage and stress development in CFRP and GF/E/CFRP composites. By shedding light on the crucial factors governing CFRP damage, we propose novel carbon-based tailored LSP materials that are lightweight and offer high performance to effectively protect the underlying composite from lightning strikes.