The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is characterized by through-thickness VectranTM stitching of warp-knit carbonabric prior to resin infusion. A series of novel lightning strike tests were performed on a PRSEUS panel. The panel’s lightning damage resistance was characterized as a function of peak current (50-200 kA) and strike location (mid-bay, stringer, frame). Both visual inspections and through-transmission-ultrasonic C-scans were used to investigate the damage resistance at the strike locations and to assess various damage mechanisms and morphologies. The size and severity of the damaged area depend strongly on the fiber orientation in the outermost ply, the amount of current injected into the panel, and the strike location relative to stitching lines. Increasing the current magnitude drastically increases the damaged area. Also, the presence of VectranTM structural stitches profoundly reduced the size and severity of lighting damage relative to similar strikes performed in panel regions without stitching.

Lightweight sandwich composite structures exhibit high strength and bending stiffness and have been used in various load-bearing aerospace structures. A primary weakness of these structures is the low interfacial strength that can result in the disbonding between the facesheet and the core. Through-thickness reinforcement techniques, such as stitching, can be utilized to improve the interfacial strength of sandwich composites. This study focuses on fabrication and structural testing of stitched sandwich composite main landing gear (MLG) strut doors. The MLG strut doors are constructed from carbon fiber non-crimp fabric facesheets and closed-cell foam core that are stitched using a modified lock stitching technique. To assess the effects of stitching, two doors were fabricated, one with and one without through-the-foam stitching. A vacuum-assisted resin transfer molding process was used to infuse the doors. The strut doors were subjected to quasi-static loading, and the mechanical responses of the stitched and unstitched strut doors are presented.