AIRCRAFT MATERIALS SELECTION GUIDE

NuSil Technology is the cutting edge manufacturer of silicone products for the aircraft industry requiring precise, predictable materials. NuSils silicone materials deliver adhesives, potting compounds, encapsulants, and fast-curing silicones. ISO 9001 certified since 1994, and AS 9100 certified since 2008, NuSil operates state-of-the-art laboratories and processing facilities in North America and provides on-site, in-person application engineering support worldwide. Benefits of Silicone Materials for Aircraft The Aircraft Industry has used silicone adhesives and coatings for over five decades. Silicones ability to maintain its elasticity and low modulus over a broad temperature range provides excellent utility in extreme environments. Recent advances in material technology provide more opportunities for the Aircraft engineer in choosing the best material for an intended application. Examples of NuSils capabilities in custom silicones for Aircraft are demonstrated in the following sections. Fuel Resistance A standard requirement for the aircraft industry is to use materials that are fuel resistant. The breadth of material choices for these types of applications is attributable to advances in Fluorosilicone technology, which are based on trifluoropropyl methylpolysiloxane polymers. The trifluoropropyl group contributes a slight polarity to the polymer, resulting in swell resistance against hydrocarbons (i.e. gasoline, jet fuels, hydraulic fluids, etc.) While some Fluorosilicones contain 100% trifluoropropyl methylpolysiloxane repeating units, other systems contain a combination of the fluorosiloxane units and dimethyl units to form a co-polymer. Adjusting the amount of trifluoropropyl methyl siloxane units in the polymerization phase provides optimal performance in specific applications. Functional fillers can be added to Fluorosilicone materials and used as gap fillers, coatings, molded parts, repair butters, or for other applications and they can also be calendared into sheets or ribbons. Operating Temperature The operating temperature range of a silicone in any application is dependent on many variables, including but not limited to: temperature, time of exposure, type of atmosphere, exposure of the materials surface to the atmosphere, and mechanical stress. In addition, a materials physical properties will vary at both the high and low end of the operating temperature range. Silicone typically remains flexible at extremely low temperatures and has been known to perform at -140 C as well as resist breakdown at elevated temperatures up to 315 C. The user is responsible to verify performance of a material in a specific application. Static Dissipation and Electrically Conductive Silicones Progression in technology has greatly influenced the use of lightweight composite materials to replace aluminum aircrafts. Aluminum has long been used for the skin and frames of aircraft, acting as a Faraday cage by spreading electrical impact along the external skin, fuselage and wings. Faraday cages protect electronic equipment from light-ning strikes, electrostatic discharges, or radar signatures. The downside to using composite materials is their inability to deflect electric charge. Electrically conductive additives incorporated into NuSils silicones provide protection against static accumulation and discharge that can damage sensitive electronic components. The static is allowed to dissipate continuously rather than accumulate and discharge rapidly. The electrical conductivity is measured by volume resistivity (cm) and is used to gauge the shielding effectiveness of the material. Electrically conductive fillers are typically metal particles (<0.1 ohmcm) or carbon black (>1 ohmcm). It is important that an electrically conductive silicone maintain its shape and conductivity under stress (i.e. elongation or compression). This provides stress relief during thermal cycling between substrates with different Coefficient of Thermal Expansions (CTEs).

Ice-Phobic Coatings Ice build up is a serious problem and major economic impact in the aircraft industry. Silicone has the ability to remain elastic at low temperatures and resistant to breakdown at high temperatures, thus making it valuable in harsh environments. Compared to other Ice-Phobic coatings and materials known to have non-stick properties such as Teflon, select silicone coatings can significantly reduce ice adhesion when applied to aerodynamic surfaces. IcePhobic coatings are useful in many applications where surfaces and structures are exposed to icing conditions: Aerodynamic Surfaces Aircraft Wings and Control Surfaces, UAV Structures, Engine Cowlings, Wind Turbines Hydrodynamic Surfaces Marine Vessels (i.e. Naval Ships, Fishing, Cargo, Ice-breakers), Lock Walls Structures Above Ground Power Lines, Roof Tops, Observatories, Antennas In a recent study, the ice adhesion strengths of Ice-Phobic coatings were tested and compared using a method developed to measure the bond strength of ice to a substrate. The force required to break the ice from the substrate surface is measured as mean stress. In the graph below, NuSils Ice-Phobic coatings show very favorable performance against the industry standard - Teflon and bare aluminum.

Mean Stress (kPa)

250 200 Teflon
(238 kPa)

Aluminum: 1520 kPa

Mean Stress ( kPa )

150 100 50 0 R-1009 8 R-1082 27 R-3930 47 R-3975 22

R-2180 37

*C oating thickness = 0.010 inches

NuSils ability to custom formulate has advanced efforts to develop alternate formulations to further accommodate Ice-Phobic applications. Currently, NuSil is evaluating new formulations that increase contact angle.

References EM 1110-2-1612, Engineering and Design Ice Engineering, U.S. Army Corps of Engineers, Department of the Army, October 20, 2002, Updated Version September 2006. Mulherin, ND, RB Haehnel, JF Jones (1998) Toward developing a standard shear test from ice adhesion. Proceedings, 8th International Workshop on Atmospheric Icing Structures, Reykjavik, Iceland, June 8-11, 1998. IWAIS 98.

AIRCRAFT MATERIALS SELECTION GUIDE

NuSil Product Number Tack Free Time Dielectric Strength V/mil Flow (Inches) Viscosity (cP/mPasec) Extrusion (g/min)

General Purpose

Comments

Cure System

Work Time

Cure Time / Temp C

Specific Gravity

Durometer Tensile Type A psi (mPa)

Elongation %

Tear ppi (kN/m)

Lap Shear psi (MPa)

Mix Ratio

Color

Properties listed are typical - Do not use as a basis for preparing specifications. Please contact NuSil Technology for assistance and recommendations
C F 1-3510 C F 2-3521 F uel / S olvent R esistant F ast C ure F uel R esistance S olvent R esistance A vailable in G ray / B lack / T ranslucent Lap S hear after 7 days Lap S hear after 7 days
*3) *1)

P latinum P latinum P latinum P latinum A cetoxy A cetoxy A cetoxy A cetoxy A cetoxy A cetoxy P latinum A cetoxy A cetoxy A cetoxy A cetoxy A cetoxy P latinum P latinum P latinum P latinum P eroxide P eroxide P latinum

6h 60 m 60 m 12 h 24 h 3.5 h 90 m

30 m 10 m 15 m 30 m 15 m 8m 20 m 20 m 20 m 10 m -

30 m / 150 30 m / 150 48 h / R .T . 48 h / R .T . 72 h / R .T ., H 72 h / R .T ., H 72 h / R .T ., H 7 d / R .T ., H 72 h / R .T ., H 72 h / R .T ., H
S ee C om m ents

1.50 1.30 1.28 1.27 1.40 1.41 1.48 1.40 1.35 1.29 1.36 1.48 1.36 1.36 1.29 1.28 1.39 1.30 1.44 1.33 1.53

25 35 35 30 35 40 40 35 35 30 50 35 40 40 40 25 S ee com m ents

175 (1.2) 750 (5.2) 600 (4.1) 500 (3.4) 850 (5.9) 600 (4.1) 700 (4.8) 850 (5.9) 850 (5.9) 450 (3.1) 1,200 (8.3) 850 (5.9) 725 (5.0) 900 (6.2) 800(5.5) 425 (2.9) 850 (5.9) 550 (3.8) 1,442 (9.9) 850 (5.9) 125 (0.86)

150 325 265 260 425 300 275 425 400 400 900 400 250 400 400 400 240 275 296 300 50

35 (6.2) 60 (10.6) 50 (8.1) 50 (8.1) 60 (10.6) 55 (9.7) 40 (7.1) 275 (48.5) 50 (8.8) 40 (7.1) 60(10.6) 50(8.1) 35 (6.2) 40 35 (6.2) 135 (22.9) 40 (7.1) *3) *4)

350 (2.4) 380 (2.6)

S ee C om m ents S ee C om m ents

400 400 -

A :70,000 / B :10 P aste T hixotropic T hixotropic T hixotropic 150 g/min 240 g/min 250 g/min 1,900 T hixotropic T hixotropic T hixotropic 1,000 to 2,000 350, 1,000 and 12,500 350, 1,000 and 12,500 A :12,000 / B :10,500 A :70 g/min / B :180 g/min 240,000 Paste

10:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 15:1

R ed T rans B lack G ray W hite B lack D k. G ray T rans T rans T rans T rans T rans G ray Lt. G ray G ray T rans G ray T rans T rans T rans T rans T rans B lack T rans T rans White

ADHESIVES & SEALANTS

C F 2-3521-2 R 7-3521-11 F S -3730 F S -3730-2 F S -3730-11 F S 1-3730 F S 3-3730 F S -3775 R -3900 R -3930 R 1-3930-11 R 2-3930-11 R 3-3930-11 R -3975 315 *3) 375 *3)

300 psi (2.1 M P a) 275 psi (1.9 M P a)

B onds A ggressively F uel R esistance, 100 m % , F ast C ure H igh T em perature, F uel R esistant
C ure: 8 h / 25 C : 45 m / 75 C : 135 M / 150 C , D ispersion C oating, 20% S olids D ispersion C oating, 60% S olids

275 T rans = T ranslucent

FLUOROSILICONES

COATINGS

72 h / R .T ., H 72 h / R .T ., H 72 h / R .T ., H 72 h / R .T ., H 72 h / R .T ., H 1 to 4 h / R .T . 45 m / 150 30 m / 150 48 h / R .T . 5 m / 116 30 m / 120 30 m / 150

240 *3) psi (1.7M pa) Lap S hear at 7 D @ R .T., H / Fed. C olor S tandard 36118 psi (2.2M pa) Lap S hear at 7 D @ R .T., H / Fed. C olor S tandard 36622 psi (2.6M pa) Lap S hear at 7 D @ R .T., H / Fed. C olor S tandard 36375 D ispersion C oating, 60% S olids F uel / S olvent R esistant F oam , 50 lb/ft (800 K g/m 3 )
Fuel R esistant Fluid
3

FOAM FLUIDS

C F 1-3710-2 F S -3600 F S -3602 F S -3606 G E L-3500 FS-3511 C F 5-3521-2 F S -3780 F S -3781 C F 1-3800
*22)

F luid, V olum e R esistivity 1x10 15 ohm scm

Fluid, V olum e R esistivity 1x10 15 ohm scm

G EL

F uel R esistant G el, D urom eter -T ype '00' 50 L i q u i d I n j e c t i o n M o l d i n g , F ast Cure Liquid Injection M olding, F uel R esistance E xtrusion or C om pression M olding Extrusion or Compresion Molding, Precatalyzed Thermally Conductive 1.25 W/mK, Fuel Resistance d = day h = hour m = m inutes R .T . = R oom T em perature H = H um idity

LSR

42 30 51 30 50

T.C.

HCR

T.C. = Thermally Conductive HCR = High Consistency Rubber LSR = Liquid Silicone Rubber

*1) P rim ed w ith S P -120 *3) P rim ed w ith S P -130 *4) P rim ed w ith C F 1-135

g/min = G ram s P er M inute

*1) P rim ed w ith S P -120 *3) P rim ed w ith S P -130 *22) = T ested A S T M C 177

AIRCRAFT MATERIALS SELECTION GUIDE

General Purpose NuSil Product Number
R -1009 R -1082

Comments

Cure System

Work Time

Tack Free Time

60 m 80 m 25 m 7m 10 m 10 m 24 h -

Cure Specific Durometer Tensile Time / Temp C Gravity Type A psi (mPa)

Elongation Tear % ppi (kN/m)

Lap Shear psi (mPa)

Dielectric Strength V/mil

1256 500 825 825 500 500 190 500 10 10 5 880 810 450 920 -

Flow (Inches) Viscosity (cP/mPasec) Extrusion (g/min)

6,500 700 3,600 3,200 3,300 A :1,300 / B :800 0.5 Inches 1.5 Inches 2 inches A :275 g/min / B :240 g/min A :265 g/min / B :250 g/min A :250,000 / B :650 P ourable 9,000 31,000 125 130 A :135,000 / B :3,750 A :140,000 / B :3,000 A :55,000 / B :45,000 4,700 3,600 600 N on-slum p 9,400 100 g/min 90 g/min S m ooth P aste P aste 65,000 P aste 75,000 1 1 1 1 1 1 1 1
*1) *3) *22)

Mix Ratio

Color

Properties listed are typical - Do not use as a basis for preparing specifications. Please contact NuSil Technology for assistance and recommendations
D ispersion C oating / C onform al, 33% S olids O ne-P art, 30% Solids C ure: 30 M / 25 C : 45 M / 75 C : 135 M / 150 C , 20% S olids C ure: 30 M / 25 C : 45 M / 75 C : 135 M / 150 C , 20% S olids F uel R esistant, High Strength F uel R esistant, H igh T em perature D ispersion C oating / C onform al, 60% S olids S olventless Low Friction Coating A dhesive, N on-slum p A dhesive, N on-slum p A dhesive E xtrem ely T ough , F ast C ure E lastom er Longer W ork T im e, Y oung's M odulus 300 psi (2.1 M P a) H igh T em perature E lastom er T herm al S tability H igh T em perature E lastom er H igh T em perature E lastom er 75 T ype D w ith Dicumyl Peroxide Catalyst (Catalyst Not Included) 75 T ype D , P recatalyzed C asting, C reating M olds C asting, C reating M olds F lam e R esistant, 25 lb/ft (0.400 g/cm ) Low D ensity / S oft, 10 lb/ft (0.16 g/cm ) M edium D ensity / S oft, 19 lb/ft (0.31 g/cm ) H igh P urity, V olum e R esistivity 1x10 8 ohm cm . S tatic Dissipation 7 ohm cm , Low viscosity 50 ohm cm , Low Durometer, T ough 0.001 ohm cm , Low / H igh T em perature 0.006 ohm cm 1.46 W /m k T herm al C onductivity 0.75 W /m k T herm al C onductivity 0.84 W /m k T herm al C onductivity 0.75 W /m k T herm al C onductivity 1 and 2 Part RTV System, 3.3% S. G eneral P urpose, 4.1% S olids G eneral P urpose, 3.5% S olids A ddition C ure S ystem s,4.5% S olids A ddition C ure S ystem s, 6% S olids A ddition C ure S ystem s, D ifficult S ubstrates, 15% S olids Improves Adhesion to Gold and Ceramic PMMA d = day h = hour m = m inutes R .T . = R oom T em perature H = H um idity
15 3 3 3 3 3 3

O xim e A cetoxy P latinum P latinum A cetoxy A cetoxy O xim e P latinum O xim e A cetoxy A cetoxy P latinum P latinum P latinum P latinum T in T in P eroxide P latinum P latinum P latinum T in T in P latinum O xim e P latinum P latinum T in P latinum P latinum P latinum P latinum P latinum H ydrolysis H ydrolysis H ydrolysis H ydrolysis H ydrolysis H ydrolysis -

> 72 h 4h 15 m 60 m 50 m 8h 6h 2h 30 d 2h > 2.5 h 22 m 10 h 8h 3h 4h 3h 2h 5h 3.5 h -

7 d / R .T ., H 5 d / R .T ., H S ee C om m ents S ee C om m ents 72 h / R .T ., H 72 h / R .T ., H 7 d / R .T ., H 30 m / 150 7 d / R .T ., H 72 h / R .T ., H 72 h / R .T ., H 2 h / 65 2 h / 65 30 m / 150 15 m / 150 7 d / R .T ., H 7 d / R .T ., H 15 m / 150 30 m / 150 30 / 150 45 m / 100 10 m / R .T ., H 10 m / R .T ., H 90 m / 80 7 d / R .T ., H 30 m / 150 60 m / 65 7 d / R .T ., H 30 m / 150 30 m / 150 30 m / 150 30 m / 150 30 m / 150 1 h / R .T . 1 h / R .T . 1 h / R .T . 30 m / R .T . 30 m / R .T . 1 h / R .T . 1 h / R .T . 30 m / R .T .

1.10 1.09 1.36 1.29 1.06 1.10 1.08 1.12 1 1.17 1.20 1.19 1.08 1.41 1.10 1.09 1.23 1.24 0.35 0.34 0.97 1.24 1.09 1.07 3.36 3.60 1.55 1.34 2.41 0.79 0.77 0.77 0.77 0.78 0.80 0.77 0.80
*1) *3)

40 25 40 40 35 25 40 30 35 30 25 45 45 20 35 35 55 S ee C om m ents

1,200 (8.3) 1,425 (9.8) 1,700 (11.7) 1,650(11.4) 850 (5.9) 425 (2.9) 700 (4.8) 120 (0.82) 850 (5.86) 600 (4.13) 1,400 (9.65) 1,050 (7.20) 1,000 (6.89) 750 (5.17) 700 (4.8) 500 (3.5) 700 (4.8) 850 (5.9) 800 (5.5) 550 (2.4) 700 (4.8) 600 (4.5) 250 (1.7) 210 (2.1) 260(1.72) 275(1.9) 700(4.8) 275(4.8) w ith w ith w ith w ith S P -120 S P -130 C F 1-135 SP-270

650 950 1,050 1,000 400 400 350 100 325 350 750 400 400 625 550 175 125 90 135 20 95 275 90 275 20 80 35 50 -

95 (16.8) 125 (22.0) 300 (52.9) 300 (52.9) 50 (8.8) 35 (6.2) 40 (7.1) 40 (7.05) 40 (7.05) 100 (17.63) 150 (26.50) 190 (33.50) 150 (25.45) 150 (26.5) 20 (3.5) 95 (14.1) 100 (17.6) 35 (6.2) 50 (8.8) 50 (8.8) 40(7.05) 65(11.5) 45(7.9) -

1:1 1:1 1:1 1:1 1:1 10:1 1:1 100:0.5 100:0.5 10:1 10:1 1:1 100:6 100:6 1:1 10:1 1:1 100:0.5 20:1 15:1 15:1 20:1 15:1 P rim ed w ith S P -120 P rim ed w ith S P -130 T ested per A S T M C 177

T rans C lear T rans B lack T rans T rans T rans T rans T rans T rans T rans T rans G ray G ray R ed R ust T rans R ed Lt. A m ber Lt. A m ber G reen G ray G ray T an T an T rans B lack B lack B lack T an T an W hite W hite G ray W hite T rans C lear R ed C lear T rans R ed T rans T rans

ICE P HOBIC

R -2180 R -2180-2 R -3930 R -3975 R 3-1075 C F 19-2615 R-1182 R -1130 R -1140 R 4-1140 R -2145 R 1-2145 R -2160 R 3-2160 R -2550 R -2560 C F -4721 C F 2-4721 R -2200-6 R -2200-11 S F M 5-2350 R -2370 R -2380 G E L-8170 R -1505 R -2630 R -2631 R -2634 R -2637 R -2930 R -2939 R -2940 R -2949 S P 1- 2 04 S P -120 S P -121

485 (3.6) 625 (4.3) *4)

ADHESIVES & SEALANTS

COATINGS

600 (4.1) 625 (4.3)

-

375 (2.6)
-

385 (2.7) 195 (1.3) -

SILICONE M OLD SILICONE STATIC GEL M AKING RESIN DISSIPATIVE FOAM

GENERAL

65 60 75 60 40 80 60 80 70 90 75 P rim ed P rim ed *4) P rim ed *5) P rim ed

ohm cm

THERM ALLY CONDUCTIVE

E. C. PRIM ER

C F 1-135 C F 6-135 C F 1-141 S P -270 S P -271

A ddition C ure S ystem s, Inhibiting E nvirom ents, 8.5% S olids H ydrolysis

E. C. = Electrically Conductive

g/min = G ram s P er M inute

T rans = T ranslucent Clear = Clear to Transparent

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