November 2013

NASA/CR–2013-218042 

LSP Composite Test Bed Design 

Arthur C. Day and Kenneth H. Griess 

The Boeing Company, Seattle, Washington
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November 2013

NASA/CR–2013-218042 

LSP Composite Susbtrate Test Bed Design 

Arthur C. Day and Kenneth H. Griess 

The Boeing Company, Seattle, Washington
Available from: 

NASA Center for AeroSpace Information 

7115 Standard Drive 

Hanover, MD 21076-1320

443-757-5802 

The use of trademarks or names of manufacturers in this report is for accurate reporting and does not 

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i

Contents

FOREWORD .................................................................................................................. III

1 SCOPE ..................................................................................................................... 1

1.1 PURPOSE ............................................................................................................. 1 

1.2 REQUIREMENTS FOR TEST BED DESIGN ................................................................. 1 

2 REFERENCES ......................................................................................................... 3

2.1 APPLICABLE DOCUMENTS ...................................................................................... 3 

2.2 NOMENCLATURE ................................................................................................... 3 

3 TESTBED DRAWINGS ............................................................................................ 4

4 ADDITIONAL OPERATIONAL INFORMATION AND SPECIFICATIONS ............. 11

4.1 INSTALLATION FEATURES ..................................................................................... 11 

4.2 CURRENT WAVEFORM SENSING ............................................................................ 11 

4.3 THERMAL SENSING ............................................................................................. 12 

4.4 MECHANICAL SENSING ........................................................................................ 15 

4.5 ABILITY TO OPERATE WITH REPEATED EXPOSURE TO THE LIGHTNING ENVIRONMENT16

4.6 OPERATING PARAMETERS TO SUPPORT HIGH-FIDELITY MODELING ........................ 17 

4.7 ABILITY TO EVALUATE INDUCED CURRENT EFFECTS FOR SYSTEMS NEAR THE TEST 

PANEL ......................................................................................................................... 18 

4.8 ADDITIONAL COMMENTS REGARDING UNITY-CORRELATION ................................... 19 
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iii

FOREWORD

The drawings shown this document were produced by Ken Griess of the Boeing 

Research & Technology (BR&T) Structures group. The general requirements and 

sensor configurations were researched and developed Art Day of the BR&T Applied 

Physics group, in consultation with Grant Erickson of BR&T Electromagnetics Effects. 

The authors would also like to acknowledge Rob Steinle of the Boeing Test & 

Evaluation organization and Ed Rupke of Lightning Technologies, Inc. (Pittsfield, MA) 

for reviewing the design and providing valuable suggestions. 

This revision provides the correct name of the company providing input to this document 

(mentioned above), and corrects typographical errors in section 4.6.2.
1

1 SCOPE 

This document provides standalone information for the LSP Composite Substrate 

Test Bed Design. A six-sheet drawing set is reproduced here for reference, as is 

some additional descriptive information on suitable sensors and use of the test 

bed. The drawings will also be transmitted as separate PDF documents, and as 

digital files in DWG format for import into most CAD programs.

1.1 Purpose 

The test bed design is deliverable 4.9 under the subject NASA contract and task 

order. The overall task order intent is to provide a Universal Common Practice 

Guide to Conduct Lightning Energy Transfer Characterizations, such that panels 

built to the set of specifications described in Reference 2.1.1 can be tested in one 

or more laboratories while ensuring a high level of consistency in test practices, 

test observations and data, and post-test evaluation methods.

1.2 Requirements for Test Bed Design 

Requirements for the design, as given in the contract Statement of Work, are 

shown in the text box within Figure 1. These requirements have been met, with 

the exception that the method of measuring currents was changed per NASA 

technical direction, as will be discussed in Section 4.
2

Figure 1: Excerpt from Statement of Work, with requirements for the Test Bed 

Design. 

The Contractor shall deliver an Engineering Design Drawing of an LSP Test Bed Fixture

(Deliverable Item 4.9). The design shall include the means to capture 

mechanical/electrical/thermal energy transfer parameters from the test article substrate 

during lighting strike tests. 

This design shall include (at a minimum) the following: 

x The LSP Test Bed shall be designed to accommodate a repeatable installation 

procedure to secure the test article substrate and eliminate test installation 

uncertainty for direct-effect testing. 

x The test bed shall be designed to facilitate measurement of lightning current 

waveforms incident on the test article substrate. The Design shall include 

current sensor placement to facilitate 2D vector current mapping. Faraday-Effect 

optical current sensors and or Rogowski Coil current sensors shall be the 

method of capturing the electrical waveform parameters transferred onto the test 

article substrate. 

x The Contractor shall define a thermal sensor capable of capturing required 

thermal parameters and be resilient to lightning energy. 

x The Contractor shall define a mechanical sensor capable of capturing required 

mechanical parameters and be resilient to lightning energy. 

x The sensors shall operate with repeated exposure in lighting environments. 

x The sensor’s operational parameters (i.e., acquisition speed, bandwidth, and 

performance resolution) shall be defined to meet requirements to support highfidelity modeling. 

x LSP Test Bed fixture shall be designed to facilitate evaluations to determine 

induced current for systems located in the vicinity of regions where 

electromagnetic coupling is present. 

x The design shall include specifications to allow unity-correlation between future 

data sets. 
3

2 REFERENCES 

2.1 Applicable Documents 

2.1.1 NASA Document # DOC-128694 – LSP Composite Substrate 

Manufacturing Processing Guide 

2.1.2 NASA Document # DOC-128695 - LSP Composite Substrate NDE 

Assessment Manual 

2.1.3 NASA Document # DOC-128695 - LSP Composite Substrate 

Lightning Test Operations Guide 

2.1.4 NASA Document # DOC-128697 – LSP Composite Substrate 

Destructive Evaluation Test Assessment Manual 

2.1.5 SAE ARP5412A – Aircraft Lightning Environment and Related Test 

Waveforms Rev A 

2.1.6 SAE ARP5416 – Aircraft Lightning Test Methods 

Parties interested in acquiring a copy of these documents and the data 

generated from this test effort are invited to contact the AEST Task Monitor, 

George Szatkowski, at his email address (george.n.szatkowski@nasa.gov) or 

phone number (757-846-6149). 

2.2 Nomenclature 

AEST - Atmospheric Environment Safety Technologies 

AI - Action Integral 

ARP - Aerospace Recommended Practice 

CFRP – Carbon Fiber Reinforced Plastic 

EME – Electromagnetic Effects 

FAA – Federal Aviation Administration 

LSP – Lightning Strike Protection

NIST – National Institute of Standards and Technology 

OML – Outer Mold Line (smooth Tool Side of Lay-up, this side is painted, and 

is also the side to be directly exposed to simulated lightning currents) 

SAE - Society of Automotive Engineers 
4

3 TESTBED DRAWINGS 

The test bed design is defined by Drawing No. 128698 sheets 1 – 6. It is shown 

in Figures 2 – 7 below. The drawing includes one page of drawing notes as 

Sheet 1 (Figure 2). The notes page includes descriptions of recommended 

materials and construction techniques. The builder of a test bed per this design 

may be allowed some leeway in materials and techniques, provided that the 

resulting structure has a comparable rigidity and does not introduce unintended 

electrical conduction paths. The notes page also includes model numbers for 

suggested current monitors and displacement sensors, for which mounting 

provisions are made directly on the test bed structure. Thermal sensing is 

expected to be by an infrared camera which is not mounted directly on the test 

bed but is able to view the panel IML surface from a distance of approx. 3 m. 

Assembly drawings are shown on Sheet 2 (Figure 3). The basic construction is a 

fastened plywood box, with large open areas for access by cameras, cabling, 

and sensors. Plywood is inexpensive and easily worked, and is of sufficiently low 

conductivity for most lightning test work. For sensor access, it will typically be 

most convenient to mount the box and panel vertically as shown in the isometric 

view. However, the box could easily be turned for horizontal panel testing.

The test panel is to be mounted over a wide aperture in part no. 128698-2 and 

secured by nine toggle clamps, part nos. -6, which apply pressure to the 

grounding bars. With four of these clamps, copper straps can be clamped to the 

grounding bars on each side of the panel. Descriptions of recommended 

grounding arrangements and strap sizes can be found in Reference 2.1.3. The 

assembly drawing shows four Pearson 4418 Current Monitors (part no. -8) 

affixed to the front of the box, positioned so that copper straps can be led to each 

of the four sides while maintaining equal strap lengths. Additional mounting 

locations for current monitor mounting are also shown, which may be convenient 

for the tester but are not required.

Three Keyence LK-G507 optical vibration sensors are shown in the assembly 

drawing as part no. -7. These are held by part nos. -5 (“Keyence Holder”), which 

are in turn mounted on the back panel, part no. -4. The Keyence Holders are 

designed so that these sensors can be moved laterally on the back panel. The 

holders also provide for rotation of the sensor beam in the vertical direction, so 

that most areas of the panel OML will be accessible for vibration measurements. 

Detailed dimensioned drawings are on Sheets 3 - 6 (Figures 4 – 7).
5

Figure 2: LSP Test Bed drawing (sheet 1 of 6) 
6

Figure 3: LSP Test Bed drawing (sheet 2 of 6) 
7

Figure 4: LSP Test Bed drawing (sheet 3 of 6) 
8

Figure 5: LSP Test Bed drawing (sheet 4 of 6) 
9

Figure 6: LSP Test Bed drawing (sheet 5 of 6) 
10

Figure 7: LSP Test Bed drawing (sheet 6 of 6) 
11

4 ADDITIONAL OPERATIONAL INFORMATION AND SPECIFICATIONS 

4.1 Installation features 

The toggle clamps specified provide up to 500 lb. each of clamping force. The 

symmetric positioning of the clamps around the periphery of the part will provide 

for easy, repeatable positioning. The clamp face pulls away entirely from the 

clamped surface so that the panel can be inserted or removed without 

interference.

4.2 Current waveform sensing 

The test bed design envisions that up to four edges of a test panel may be 

independently grounded and sensed. Based on the intended peak current test 

levels of 100 kA, 40 kA, and 20 kA, a Pearson 4418 was selected as an 

appropriate current monitor. Pearson current monitors are widely used in 

lightning and pulsed-power labs. The 4418 is rated for a peak current of 200 kA 

and a total charge transfer capability (I-T product) of 6 Coulomb when biased, or 

2 Coulomb without biasing. When testing with lightning waveforms B and C, the 

user should check the detected charge transfer to be sure that these limits are 

not exceeded, or inaccuracy may result. The user should also take care that 

these monitors are not subject to high fields and voltages, since they are singleisolated rather than double-isolated. It is common practice (and recommended) 

to wrap a thick Mylar sheet around grounding straps where they feed through 

current monitors. 

Other current probes such as the Pearson 1423 could be used in place of the 

4418. These provide higher I-T product, but are significantly larger and would 

have to be located on a secondary support. In such cases, the user should keep 

the grounding strap lengths from changing beyond the limits described in 

Reference 2.1.3.

The SOW for this task called for use of Faraday Effect current or Rogowski 

current probes. The NASA technical focal originally expected that the test bed 

would accommodate one or more such probes which were under development at 

NASA, but in the course of monthly progress meetings, Boeing was told that 

these probes were not now ready for this application. The use of Pearson-type 

probes was discussed and agreed to at one of the monthly Boeing/NASA 

telecoms.
12

4.3 Thermal Sensing 

Thermal data have been used at Boeing and elsewhere as a diagnostic to 

quantify energy deposition on test panels and other evaluation purposes. Boeing 

has been successful in using a SC640 ThermaCAM from FLIR Systems, 

including through approximately 20 lightning tests. This model can be batteryoperated and, if desired, the data can be streamed to a laptop computer over a 

FireWire connection. Basic specifications are given in Table 1 below. Based on 

Boeing experience, IML temperature profiles can be accurately sensed with 

frame rates on the order of 2/second, so the SC640 is more than adequate. Very 

advanced users may wish to conduct thermography on the OML as well, but the 

risk of plasma flash damage to IR equipment is such that these users will have to 

develop their own operational requirements depending on the experimental 

conditions.

Table 1: FLIR Systems SC640 specifications 

In the Boeing application, both the camera and a laptop were placed in a lightly 

shielded wooden box, with a hole cut for lens access. Shielding consisted of 

medium-duty aluminum foil. The camera was located approximately 3 m behind 

the test panel. A photo of the lab setup is shown in Figure 8 and a photo of the 

box (with an access door removed) in Figure 9. Further information on usage is 

given in Section 4.6. 
13

Figure 8. Boeing Lightning Laboratory with test panel (left) and shield box for camera 

and laptop (right) 

Figure 9: Shield box with camera and laptop, with access door removed. 
14

The data obtainable with this system in lightning tests can be accurate to within a few 

degrees C and provide high spatial resolution. Two examples are given in figures 10 

and 11 below. 

Figure 10: IML temperatures following a typical test. Peak temperature = 81C. 

Figure 11: Unusual IML thermal pattern resulting from flaming fibers on OML. 
15

4.4 Mechanical Sensing 

The mechanical response of a panel under lightning strike can be highly variable, 

depending on thickness and sometimes added systems or stiffening structures. 

Shock effects may have a bearing on panel puncture. When underlying systems 

are part of a test, it is especially important to guard against unintended forces 

and deflections of such systems toward the panel due to inductive effects.

A trial was made of a high-bandwidth optical position/vibration sensor in the 

Boeing Lightning Laboratory. The sensor was the LK-G507 from Keyence. The 

sensor operated through repeated strikes of up to 100 kA (full Zone 2A) using the 

setup shown in Figure 12. The sensor is approximately 20” behind the test panel, 

and a cable leads to a laptop which is operated on battery power. The sensor is 

also powered by a 24 V power supply, which for this test was operated from an 

Uninterruptible Power Supply (UPS). A position waveform from the sensor is 

shown in Figure 13 as it appeared on the laptop screen. 

Figure 12: Test run of Keyence optical position/vibration sensor. 
16

Figure 13: Position vs. time on Keyence sensor. Bandwidth for this run = 1 kHz. 

To support high-fidelity modeling, it is recommended that vibration sensor have a 

bandwidth that is at least 1 kHz, which will typically allow it to sense lower-order 

vibration modes of a panel. The Keyence LK-G507 can theoretically attain 50 

kHz although at Boeing no tests were run above 10 kHz. It should also have a 

spatial resolution of 0.1 mm or better.

Setup for laser-reflection sensors will typically consist of mounting the sensors to 

the rear face of the test bed. The Test Bed provides a design for holding plates 

for up to three Keyence model LK-G507 sensors, such that their output beams 

can be adjusted to the desired sense point. These sensors send data directly to a 

portable computer which should be operated on battery power during a test.

4.5 Ability to Operate with Repeated Exposure to the Lightning 

Environment

As described above, both the FLIR Systems IR camera and the Keyence optical 

sensors have been checked in the Boeing Lightning laboratory. Repeated shots 

were done with these sensors operating properly and showing no damage or 

degradation in performance. Current probes similar to the Pearson 4418 have 

also been operated in the Boeing laboratory for many years. As with any highvoltage test, poor lab practices can result in equipment failures or serious 

injuries. To the best of our knowledge the sensors described herein are not 
17

particularly sensitive to EMI but can be operated successfully by prudent 

engineers familiar with lightning test environment. 

Setup for an IR camera will typically require a camera to be mounted on a tripod 

and located approximately 3 meters behind the test panel. It may also be 

connected to a portable computer so that a video stream can be recorded over 

several minutes. To prevent interference or damage during the test, both of these 

should be operated on battery power. It is further recommended that they should 

be located in a box that provides some shielding against high frequencies. 

Medium-gauge aluminum foil has been found suitable but results may vary with 

camera and computer models. 

4.6 Operating Parameters to Support High-Fidelity Modeling 

Boeing’s approach to this question is necessarily subjective, but the general 

approach taken has been to design a test bed that provides features for testing 

and modeling which are as good as or better than anything we are aware of in 

the leading laboratories today. Characteristics of recommended sensors have 

been described in previous sections of this document, and are more fully detailed 

in manufacturer’s operating manuals. Other operating parameters for testing 

have been well-described in the other documents produced under this Task 

Order, which are listed as references in Section 2. 

4.6.1 Surface Emittance Determination 

If IR thermography is used to record panel surface temperatures following a test 

strike, accuracy of the temperature depends on having a valid estimate of the 

surface’s thermal emittance. For paints and composites, this number is typically 

between 0.7 and 0.95. This number should be measured (the preferred method) 

or otherwise determined to an accuracy of ± 5%, or errors of 10 degrees Celsius 

or more may result. An infrared reflectance or emittance measurement is needed 

to determine the thermal emittance, since optical properties in the thermal IR (the 

8 – 14 micron wavelength band seen by most IR cameras) can be very different 

from the properties at visual wavelengths. Suitable instruments for measuring 

emittance include the Gier-Dunkle DB100 and the AZ Technology TEMP 2000A. 

It is also acceptable to apply a known high-emittance paint to the back of a panel, 

rather than (or on top of) standard aircraft paints. A thin layer less than .010” 

thick will result in no detectable change in surface temperature over the multisecond heating that is to be expected. 
18

4.6.2 Additional Operating Suggestions for Sensors during Simulated 

Lightning Attachments 

This section includes typical procedures for IR and optical vibration sensors, but 

actual procedures may require some modification based on the specifications 

and operating manuals of the available equipment. 

The IR and vibration sensors described in the sections above can both be 

operated via battery-operated laptops that are located in the test cell. Data 

acquisition can be started and personnel evacuated from the cell prior to 

charging the banks.

Prior to initiating the data sequence, focus the IR camera on the rear of the test 

panel. Enter settings in the camera or its dedicated software package for the 

panel’s surface emissivity, as well as distance, room temperature, and humidity. 

The data storage rate (in frames per second) may be adjustable and rates from 1 

frame per second to 30 frames per second may be suitable because CFRP 

panels typically require 10 seconds or more to reach maximum temperature on 

the OML. Verify that the camera shows room-temperature objects to be within +/- 

3 degrees Celsius of the known ambient temperature. Unplug the camera and 

associated computer from line power. Initiate data streaming from the camera to 

the computer. 

Prior to initiating data acquisition, locate optical vibration sensors so that the 

laser spot is directed to the desired location for the vibration measurement. The 

Test Bed allows freedom of lateral positioning of the sensor bodies on the rear 

panel of the box, and freedom of the vertical beam alignment by rotating the 

sensor bodies on a holding plate. Set the frequency response of the sensor via 

its associated control software: Typically, 1 kHz will be sufficient. Set the 

acquisition time window to a value that will allow for vacating the room and for 

the charge and discharge times of the test current generator. Initiate data 

streaming from the sensor(s) to the computer. 

4.7 Ability to Evaluate Induced Current Effects for Systems Near the Test 

Panel 

Aircraft systems runs are often located in close proximity to aircraft skins, and 

these may be subjected to transient fields and forces when simulated lightning 

testing includes such systems. Because systems vary enormously in size, shape, 

and distance requirements, no special fixturing has been built into the LSP 

Substrate Test Bed. However, the test bed box allows easy access to the back of 
19

the test panel through all four sides. C-clamps can be used to hold additional 

cross-pieces to the box for mounting of tubes or cables. Alternatively, the box 

can be modified with the most basic hand or power tools. 

4.8 Additional Comments Regarding Unity-Correlation 

Boeing has striven to keep the test bed design simple, while also allowing some 

flexibility for operator convenience. The instrumentation recommended here was 

selected based on practicality and affordability for an ongoing lightning test 

operation. The procedures and specifications in the referenced documents 

should be sufficient for enabling a high degree of correlation of results between 

testers.

Ultimately, the ability to correlate results from one laboratory to another rests with 

the operators and with the coordination given them. In particular, any deviations 

from the referenced documents or from manufacturer’s recommendations should 

only be allowed if justified by sound engineering analysis of such deviations, and 

documentation of the rationale.
REPORT DOCUMENTATION PAGE Form Approved

OMB No. 0704-0188

2. REPORT TYPE 

Contractor Report

 4. TITLE AND SUBTITLE

LSP Composite Substrate Test Bed Design 

5a. CONTRACT NUMBER

NNL10AA05B

 6. AUTHOR(S)

Day, Arthur C.; Griess, Kenneth H.

 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

NASA Langley Research Center 

Hampton, Virginia 23681 

 

 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

Washington, DC 20546-0001

 8. PERFORMING ORGANIZATION

 REPORT NUMBER

Document Number: DOC-128698, rev 1

10. SPONSOR/MONITOR'S ACRONYM(S)

NASA

13. SUPPLEMENTARY NOTES

Langley Technical Monitor: George N. Szatkowski

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Availability: NASA CASI (443) 757-5802

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Composites; Lightning

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