Enhancing Lightning Strike Protection of CFRP Laminates Using Nickel-Coated Carbon Fiber Nonwoven Veils

The lightning strike protection (LSP) performance of nickel-coated carbon fiber nonwoven veils (NiCVs) with varying areal densities, integrated onto the surface of CFRP laminates, was evaluated through simulated lightning strike tests. Post-strike damage was evaluated through visual inspection, non-destructive ultrasonic testing, residual strength measurements, and microstructural examinations. Results indicated that the protection effectiveness improved with increasing NiCV areal density. The laminate with a 68 g/m² NiCV layer showed substantially reduced damage—its damage volume, damage area, and maximum damage depth decreased to 18%, 40%, and 51% of those of the control laminate—and it retained 95% of the reference compression strength, demonstrating the strong post-strike protection capability of this lightweight veil. A detailed analysis suggested that the NiCV LSP performance may arise from a mechanism involving high electrical conductivity, a thermally stable coated-fiber skeleton, as well as a distributed nonwoven network architecture. These results highlight NiCV as a promising functional approach for enhancing the lightning strike protection of CFRP aerostructures.