Advancements in Lightning Strike Damage Modeling: Finite Element Model to Predict Thermal Damage Induced on Composites

Modern aircraft, ships, and offshore structures are increasingly constructed using fiber-reinforced composite materials. However, when subjected to lightning strikes, these materials can suffer significant structural and functional damage due to their electrical and thermal properties. This study aims to develop a novel finite element (FE) model to minimize the error in estimating the thermal damage caused during lightning strikes. This will aid in design and optimization of lightning protection systems. The developed model introduces a simplified numerical approach to model the lightning arc interaction with CFRP laminate. The existing FE model includes idealized loading conditions, leading to high error in estimation of severe damage area and in-depth damage. The proposed methodology incorporates a more realistic lightning-induced loading pattern to improve accuracy. Several cases are analyzed using available FE methods and compared to the proposed model (case 6) to evaluate the extent of damage. The thermal damage results are validated against baseline experimental data, demonstrating that the proposed FE model reduces the error from over 40% (observed in rest of the cases representing existing FE approaches) to within 10%.