Thermoelectric and Ignition Effects of Lightning Strikes on Composite–Metal Lap Joints

Carbon fiber-reinforced polymer (CFRP) composite–metal joint structures are susceptible to localized discharge and thermal damage under lightning current, posing serious safety concerns for critical aircraft components such as fuel tanks. In this study, we investigated the conductive behavior of composite–metal lap joint structures subjected to multiple continuous lightning current components (A, B, and C*) through a combination of experimental testing and numerical simulations. The effects of fastener assembly methods on ignition events were systematically examined, and the ignition source generation mechanisms under interference-fit and clearance-fit conditions were revealed. The protective performance of different assembly approaches against ignition sources was also evaluated. The results indicate that the assembly type and installation method have a pronounced influence on the ignition threshold and damage modes. Specifically, interference-fit joints with wet installation exhibited no ignition even at a current of 91 kA, whereas clearance-fit joints without wet installation generated potential ignition sources at 14 kA. Wet installation effectively increased the ignition threshold by approximately twofold. Copper mesh on the composite surface played a crucial role in current conduction. The simulation results further demonstrated that the current became concentrated at the composite–metal interface upon removal of the copper mesh, causing local temperatures to exceed the resin pyrolysis temperature (893 K), thereby creating potential ignition sites. This study enhances the understanding of lightning ignition mechanisms in composite–metal lap joint structures and provides both theoretical and experimental foundations for improving lightning protection design in aircraft fuel tank structures.