Modeling and simulating the lightning phenomenon: aeronautic materials comparison in conducted and radiated modes JAZZAR Ali(*), CLAVEL Edith(*), MEUNIER Gérard(*), VINCENT Benjamin(*), GOLEANU Anca(*), VIALARDI Enrico(+) (*) G2elab, BP 46, F-38402 Saint Martin d’Hères Cedex, France Email: Ali.Jazzar@g2elab.grenoble-inp.fr (+) CEDRAT, 15 Chemin de Malacher – Inovallée – 38246 Meylan Cedex – France Abstract- The composite materials are becoming more and more used in aircrafts design. Their light weight and their excellent robustness make them attractive compared to metallic materials which have been widely employed till now (aluminum for instance). However, an important drawback is their electric conductivity which is quite weak compared to the metallic one. Thus, in case of lightning phenomenon, the outside circulating current is not evacuated in the same way as in aluminum structures with possible damages to the on-board devices. The objective of this article is to compare the performances of two cylindrical samples made of composite and aluminum respectively. The PEEC (Partial Element Equivalent Circuit) method is applied to model their electrical behavior in terms of an equivalent circuit, which is then supplied with the standardized lightning current in order to evaluate its impact upon the structure. The conducted and radiated EMC modes are both investigated by means of two different test-cases. Conclusions concerning the level of currents, frequency range involved and EMC performance are then drawn. Keywords: PEEC method, lightning, eddy currents, conducted and radiated current density. I. equipotential parts seem to be critical problems via electric network function. In this context, another parameter has to be taken into consideration: the current in the composite itself. Since these currents can cause local heating and degradation, they have to be very well controlled. It is also necessary to model the behavior of the entire composite structure power including frames and other conductive parts, in order to be able to characterize current circulating in the skin [6-12]. The aim of this article is to show that a representation with a global equivalent electrical circuit of the 3D studied device as well as its environment could be used to evaluate the partitioning and the distribution of the lightning current in the different elements of the electrical architecture. This paper is focused on one of the most critical parts of an aircraft: the nacelle where jet engines are hosted (Fig. 1) and where some cables are routed inside or outside the cylindrical structure. That’s why the studied test-case is constituted by an open (in the sense that is devoid of the bases) cylinder and some rectilinear conductors. INTRODUCTION The last forty years have shown a progressive increase in the percentage of composite CFR (Carbon Fiber Reinforced) materials used in the aircraft structures. These materials weight is less than metals and provide better stiffness and mechanical strength. In addition, composite structures last longer due to a greater time-to-failure and their resistance against corrosion. For all these reasons, composite structures promise longer periods between maintenances and less fuel consumption, so they become interesting for aircraft manufacturers and airline companies. However, since their electrical conductivity is weak compared to the metal’s one, they cannot evacuate lightning current as well as aluminum [1-2]. So for the new aircraft systems, the evaluation of a new electrical architecture is required in order to lead to engender an optimal protection against lightning. The development of the embedded electrical network in the aircraft taking into account this new electromagnetic environment has raised fundamental questions concerning the protection of on-board devices through this electrical network: its behavior during lightning and the identification of Fig. 1: Real aircraft configurations to study the lightning effect In section II, the geometry and the electrical configuration of the studied cases are detailed. The modeling approach is then presented in the section III. For the conducting parts, the PEEC method is used to obtain an electrical equivalent circuit. The principles of this method are also briefly recalled. To model the lightning waveform, the data given by standards are exploited and the time-domain definition of the lightning current is shown. Results will be analyzed in section IV. Not only is the global current inside the structure evaluated but also the current density in the cylinder and the equivalent impedance of the entire study case. A precise modeling via adapted simulation tools will be presented taking into account this complex electromagnetic environment. The use of a circuit solving process makes it possible to evaluate the time-domain waveforms of current inside the structure. The advantages of this modeling approach will be detailed as well as the results. The Vth section underlines the main advantages of the modeling process for aeronautic purpose as well as the further works which are in progress. II. THE STUDY CONFIGURATIONS A. The geometry of the studied cases The geometry of the studied cases is a cylinder of thin thickness whose material can be aluminum or composite. Indeed, one of the aims will be to identify the physical phenomenon of the current distribution in this cylinder correlated with its material. Some cables are added to this geometry to define different electrical configurations. A graphical sketch of the geometry is presented in Fig. 2 and 3. The geometrical parameters of this study are the following: • the length of the cylinder and the cables is one meter: length of maximal size in the aim to simulate (reducing unknowns number), without furthering the side effect; • the cylinder diameter is one meter; • the cylinder thickness is 2 mm; • the cables section is 25 mm² B. The electrical configurations As depicted in Fig. 2 and 3, a current source, representing the lightning strike, is used to supply the cylinder: it represents the lightning strike. The current return is ensured using a cable, which is connected between the load and the source. For the first studied case, the conducted mode is evaluated. Thus another cable A is directly connected to the cylinder (Fig. 2). The objective of the second studied case is to evaluate the radiated mode. The same cylinder with the same current injection is used, but two aluminum cables are added, one outside the cylinder, the other one inside. They are connected to each other so that the evaluation of the induced currents on these cables (Fig. 3) can be performed. For these two studied cases, the current distribution is a key point in order to identify which part is overloaded according to the cylinder material and the electrical configuration. Fig. 2: Electrical configuration to study the conducted mode Fig. 3: Electrical configuration to study the radiated mode The different physical parameters of this study are following. • the composite conductivity is 5000 S/m • the aluminum conductivity is 4E7 S/m • the frequency range is from 100Hz to 10MHz In this study, the composite material is considered homogenous. Since the objective of this study is to compare the two materials in different configurations, exact values are not necessarily expected. Behavior trends enabling us to understand their impact are searched. So the values for the resistivities of composite and aluminum are voluntarily chosen so distinct in order to emphasize the differences. In reality, we know that according the composite material which is used, the factor between the two values can vary a lot. III. MODELING METHOD The aim of this paper is to predict the current distribution inside an electrical structure after a lightning phenomenon. So the best suitable model is an electrical one. Thus, an electrical equivalent circuit of the conducting parts of the studied device has to be found. Moreover, the lightning phenomenon has also to be modeled in order to supply the previous model with it. A. The conductors model For Power Electronics applications, the PEEC method [8-910-11-13] has proved to be very efficient. This is an integral method which allows a precise and complete approach of the phenomenon, without presenting the weight of the finite elements method because it does not require meshing the surrounding air. When applying the PEEC method, the current density inside the conductors must be uniform. But, for the studied application, the frequency range needs to take into consideration the skin effect as well as the proximity effect. So the current density is not uniform inside the conductors. A conductors meshing must then be applied. To be efficient, equivalent of keeping a reasonable number of PEEC elements, the meshing of conductors is directly linked to the possible assumption upon the current way. So a unidirectional conductor means that current goes one way (Fig. 4) whereas a bidirectional conductor is a thin conductor where current flows along two directions. For a unidirectional conductor, the meshing concerns the cross section and leads to PEEC elements of lower cross section for which current density is supposed to be uniform. Each element of the meshing is modeled by an R-L series equivalent circuit. All partial inductances are coupled together by means of mutual inductances. All circuits are associated in parallel so that a simple R-L series equivalent circuit is sufficient to translate electrical behavior of a unidirectional conductor (Fig. 4). This meshing has been used for the cables. For the cylinder case, a 2D mesh has to be used because for this conductor, the assumption of only one current direction is not possible (Fig. 5). Moreover, two skin effects are involved when frequency increases. The first one, which is the most important, is modeled using a surface meshing as presented on Fig. 5. The second one, which occurs in the thickness of the conductor, has been neglected in this study but it has to be kept in mind to refine the model. In the case of AC steady-state analysis without magnetic material, the use of PEEC method will consist in calculating the value of the partial resistances, partial inductances and all mutual inductances between them from the geometrical characteristics of each element of the meshing. The A-type temporal shape of the lightning current is represented on Fig. 6. The current is bi-exponential as the following form in (1) with α = 11345 s-1, β = 647265 s-1 and I0=200 kA: i (t ) = I 0 ( e −α t −e −β t ) (1) The Fourier transform is applied (2). It can be noted that the great part of the energy of the lightning signal is concentrated in the low frequency range, up to 10MHz (Fig. 7). This allows justifying the non evaluation of parasitic capacitive effect. 1 1 (2) I ( jω) = I0 − α j ω β jω + + Fig. 4: The principle of the unidirectional meshing Fig. 6: Model of the current wave associated to the lightning Fig. 5: The principle of the bidirectional meshing This electrical model is suitable for quite low frequencies. Parasitic capacitances should have to be added in order to model the high frequency behavior and resonance phenomena, as it has been achieved in [14-15]. For the studied cases, the first step presented in this paper consists in taking into account only the inductive behavior and in concluding upon the truth of this assumption. Once the complete and quite complex equivalent circuit is evaluated, it is necessary to add the supply source and all other components (load…) and to solve the circuit equations associated to this circuit. This illustrated PEEC method is implemented in the InCa3D® software [7] that is used in this study. B. The lightning model The aim of this study is to reproduce faithfully the current distribution when a lightning strike occurs on the aircraft and to evaluate the consequences on the on-board equipments. Lightning is a natural dangerous phenomenon whose influence on electrical systems can go from the dysfunction of equipments to their destruction. Lightning is not just light between two clouds or inside one cloud. It is produced many kilometers up in the sky and makes every airplane in this zone vulnerable. Since it is not easy to predict a lightning occurrence, the objective of scientists is to predict and control its impact on the electrical equipments. As presented in standards, the waveform of the lightning current is defined as an electrical arc wave which has precise characteristics (intensity, time, di/dt). Several waves’ shapes according to the studied phenomenon are associated [3-4-5]. Fig. 7: Fourier transform of the current wave associated to the lightning IV. RESULTS A. Modeling of the studied cases The previous geometries have been described into InCa3D and simulated. The available data at the end of the first phase of solving are an electrical equivalent circuit with great numbers of elements (according to the meshing assumptions). Then a source is added to supply the system and to evaluate the current density distribution in each conductor. In order to obtain the total current inside the cable or at the inputs of the cylinder a simple sum of phases is made. Another important output provided by InCa3D is the equivalent impedance of the studied device from its inputs and outputs. In the following these different results are detailed for the studied cases in the two electrical configurations. B. Current density in the cylinder The current distribution on the surface of the composite cylinder is drawn on Fig. 8 at the frequency of 10 kHz. This computation is performed by injecting a current of 200 kA between two opposite sides of the cylinder and no cables are included in the simulation, in order to estimate the distribution of current in case of a lightning phenomenon. The current is very high at the injection points and quickly decreases from this point. So according to the position of the internal cables compared to these points, the induced effect due to the lightning will have more or less influence on electrical equipments. circulate on the metallic surface of the airplane (Fig. 10). A low quantity circulates in the internal elements (cables…). The current in the cylinder structure is the same for the whole frequency range and it is equal to the injected current. 2. Radiated mode In the case of the radiated mode (Fig. 3), the lightning current inside the cylinder implies a magnetic field all around the structure. According to the electrical circuit and its geometry, induced currents can appear and damage the electrical equipments. For the studied cases, the induced current in the cable has been evaluated and is presented in Fig. 11. A first analysis shows that this current is almost the same for the two cases of material for the cylinder. Fig. 8: Current distribution at the surface of the cylinder at 10 kHz C. Global current distribution The most important consequence of using the composite material is the redistribution phenomenon: the circulation of the lightning current on a composite material airplane differs from the metallic traditional airplane. In general, the lightning current flows into the less impedance parts of the aircraft, i.e. those being the less inductive in high frequencies and the less resistive in low frequencies. So the highest frequencies of the lightning circulate preferentially on the nacelle, composite or metallic. And the lowest frequencies of the lightning circulate on the parts that are less resistive. They are distributed on the nacelle and the cables, proportionally to their resistance. 1. Conducted mode In the case of the composite airplane, the low value of the conductivity of the nacelle leads to the major part of the low frequency lightning current circulating in the internal metallic elements which are better conductors. This is the current redistribution phenomenon: in case of a lightning, the internal currents can present a high intensity and a longer duration that exceeds those of the lightning phenomenon (spectral content at low frequency), and also a high energy. On Fig. 9 and 10, global current in the cable and the cylinder is drawn for the metallic and the composite cylinder, in the case of conducted propagation mode (Fig. 2). In the case of composite material, one quarter of the current flows into the cable (aluminum) for low frequency. When the frequency increases the current in the cable decreases until it becomes null. Conversely, the cylinder carries the other three quarters of the lightning current at low frequencies and the all of it at high frequencies (Fig. 9). So the use of a composite material can lead to problem in case of lightning at low frequencies. In the case of an entire metallic airplane, the resistance of the fuselage is weak, and the majority of the low frequencies Fig. 9: Redistribution of the current in the aluminum cable and the composite cylinder (conducted mode). Fig. 10: Redistribution of the current in the aluminum cable and the aluminum cylinder (conducted mode). Fig. 11: Induced current on the cable A in the case of cylinder made of aluminum or composite (radiated mode). According to Fig. 11, the same induced current in the aluminum cables is observed in both cases of material for the cylinder. The resistive effect appears for low frequency, then as the frequency increases, the predominant effect is inductive. D. Equivalent impedance InCa3D is also able to reduce the complete equivalent circuit given by the solving in order to evaluate the impedance of the cylinder between the two points of the current injection. These two points are defined on Fig. 12. Fig. 14: Inductive part of the equivalent impedance of the cylinder. Fig. 12: The two points to evaluate the equivalent impedance of cylinder. Fig. 13: Resistive part of the equivalent impedance of the cylinder. Resistive and inductive parts of the equivalent impedance are drawn for both composite and aluminum cylinder in Fig. 13 and Fig. 14. The mesh density is important to fully capture the skin surface effect (in relation with increasing frequency). The figures shown here correspond to "sufficiently meshed" geometries ( the values are stabilized despite the increasing mesh density). Nevertheless, the range of value is respected. To easily simulate the time variation of the current waveform, the resistance and inductance of the equivalent electrical circuit of the cylinder have to be constant across the frequency range of the injected current (Fig. 7). For our study case and with composite materials (Fig. 13), the resistance and the inductance are constant up to 100 kHz. After which the resistance starts increasing due to the skin effect, contrary to the inductance part which decreases. This behavior is quite different for the aluminum case, where the skin effect occurs for lower frequencies. A meshing of only the surface of the bidirectional conductors seems not to be sufficient to give accurate results. A finite elements model using Flux® software [7] is under work as well as development of new meshing techniques for PEEC method. E. Time domain simulation With using of the PEEC method via the present version of InCa3D, only a harmonic analysis can be undertaken as previously presented. But the lightning is a time phenomenon as shown on Fig. 6. Thus, a time simulation could be very useful to conclude on its effect on electrical on-board equipments. To reach this pertinent information for the industrial aeronautics, an equivalent electrical circuit of the studied structure is extracted from InCa3D at a given frequency. This frequency is chosen from the previous results. In fact the variation of equivalent impedance with frequency is not significant and this parameter has very little impact on the results. An equivalent circuit can be extracted from InCa3D and imported into electrical software. For this study, Portunus® [7] has been chosen because it is automatically linked with InCa3D. Then the lightning current is described with the data of standards and the effect on cables can be evaluated. This modeling process has been achieved on the structure presented on Fig. 15 where several aluminum cables inside the composite cylinder have been described. The first results of the cylinder with many cables inside are shown on Fig. 16. It can be noted that according to the cable and its position, in relation with the injection of the lightning current, the current is different. So a great attention has to be paid to the cabling inside the aircraft because according to its position and its geometrical parameters, the impact of a lightning on the electrical equipments could be different. We observe that during the first microseconds and during the transitional regime (high frequency), the current flows further in the composite material (less inductive). However, when time passes (low frequency), the current tends to flow only in aluminum (less resistive). limit the computation time. Research works in that way are currently in progress [14-15]. Further works are in progress to also evaluate the magnetic field near the electrical equipments since the values of induced currents are then known using the proposed modeling. The induced phenomena via magnetic couplings are supposed not to be negligible. The final aim is in fact to propose some rules to better cable some areas in the aircraft. Since a parametric description is possible inside InCa3D analysis, the best position of cables could be found, using optimization process. The most critical areas are those where lightning often occurs. ACKNOWLEDGMENT Fig. 15: Cylindrical structure with many cables inside This work is a part of a great French research program called PREFACE. Authors want to thank the sponsors of this project which are ASTECH: Hispano-Suiza, AESE: Safran Engineering Service, PEGASE: Eurocopter. REFERENCES [1] [2] [3] [4] [5] Fig. 16: Time response of the current in the cables in case of a lightning. V. CONCLUSIONS In this paper, a modeling approach has been proposed to predict the influence of a lightning impact on an aircraft or on a part of it, the nacelle for instance. A PEEC method and a timedomain solving have been jointly used to evaluate the current waveforms inside the cables routed near the injection points. A simple structure of a cylinder with some cables has been used as an example to show the different behavior of composite material compared to aluminum on the current distribution in case of conducted or radiated mode. For composite structures, the major problem remains for low frequencies, where a great quantity of current flows in the cables with possible damages to the on-board equipments. Conversely, for high frequencies, the influence of the structure material is less important since, the current redistribution phenomena are leaded by the geometrical sizes. 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