Washer assembly with seal for lightning-protection fasteners and method of manufacture

1. A washer assembly comprising:

a metallic washer defining a cylindrical void and an axis therethrough; and

a polymer seal attached to the metallic washer and positioned radially inward thereof, the polymer seal comprising:

a lower seal portion positioned at least partially within the cylindrical void and defining a counter-bore, the lower seal portion configured to engage, at the counter-bore, a fastener to form a seal to reduce escape of energized particles; and

an upper seal portion extending axially from the lower seal portion, the upper seal portion configured to engage a counter-bore of a counter-bored nut to form a seal inside the counter-bored nut to reduce escape of energized particles, wherein the lower seal portion comprises a polymeric annulus having:

a radially inner surface that bounds the counter-bore and extends axially beyond the metallic washer in a direction opposite the upper seal portion;

a radially outer surface coextensive with the metallic washer; and

a fillet extending between the radially inner surface and the radially outer surface.

2. The washer assembly of claim 1 , the washer assembly further comprises a dielectric material coating the metallic washer.

3. The washer assembly of claim 2 , wherein the metallic washer comprises a metallic annulus, including:

a radially inner surface bounding the cylindrical void, the cylindrical void passing centrally through the metallic washer;

a radially outer surface; and

opposing axial end surfaces, wherein the dielectric material coats at least the radially outer surface and the opposing axial end surfaces of the metallic annulus.

4. The washer assembly of claim 3 , wherein the dielectric material further coats the radially inner surface of the metallic annulus.

5. The washer assembly of claim 1 , wherein the upper seal portion comprises a polymeric annulus having:

a radially inner surface that bounds the cylindrical void;

a radially outer surface and an axial end surface distal of the counter-bore defined by the polymer seal; and

a fillet extending from the radially outer surface to the axial end surface.

6. The washer assembly of claim 1 , wherein the lower seal portion is configured to engage, at the counter-bore, a sleeve of a sleeved fastener to form a seal over the sleeved fastener.

7. The washer assembly of claim 1 , wherein the lower seal portion is configured to engage, at the counter-bore, a shank of a cylindrical fastener to form a seal over the cylindrical fastener.

8. The washer assembly of claim 1 , wherein the lower seal portion is configured to engage, at the counter-bore, a cylindrical-shank fastener to form a seal over the cylindrical-shank fastener.

9. The washer assembly of claim 1 , wherein the polymer seal comprises a polymer selected from the group consisting of:

polyamide-imide (PAI);

polyimide (PI);

polyaryletherketone (PAEK);

polyphenylene sulfide (PPS);

polyphenyl sulfone (PPSU); and

polyaryl ether sulfone (PAES).

10. The washer assembly of claim 1 , wherein the polymer seal further comprises a filler material distributed throughout a polymer material from which the polymer seal is formed.

11. A method of manufacturing a washer assembly for a lightning-protection fastener, the method comprising:

forming a washer from a metal material, the washer defining a cylindrical void and an axis therethrough;

forming a seal from a high-strength polymer material, wherein forming the seal comprises machining the seal from the high-strength polymer material, the forming including:

forming a lower seal portion defining a counter-bore, the lower seal portion configured to engage, at the counter-bore, the lightning-protection fastener to form a seal to reduce escape of energized particles, and

forming an upper seal portion extending axially from the lower seal portion, the upper seal portion configured to engage a counter-bore of a counter-bored nut to form a seal inside the counter-bored nut to reduce escape of energized particles; and

attaching the seal to the washer in the cylindrical void.

12. The method of claim 11 further comprising coating the washer with a dielectric material.

13. The method of claim 11 , wherein forming the washer comprises machining the washer from the metal material.

14. The method of claim 11 , wherein forming the seal comprises injecting the high-strength polymer material into a mold defining the lower seal portion and the upper seal portion.

15. The method of claim 11 , wherein attaching the seal to the washer comprises inserting the seal into the cylindrical void.

16. The method of claim 15 , wherein attaching the seal to the washer further comprises applying an adhesive between the seal and the washer.

17. A method of manufacturing a washer assembly for a lightning-protection fastener, the method comprising:

forming a washer from a metal material, the washer defining a cylindrical void and an axis therethrough;

inserting the washer into tooling for molding a polymer seal in the cylindrical void, the tooling comprising:

a lower seal mold configured to form a lower seal portion, the lower seal mold defining a counter-bore, the lower seal portion configured to engage, at the counter-bore, the lightning protection fastener to form a seal to reduce escape of energized particles, and

an upper seal mold configured to form an upper seal portion, the upper seal mold extending axially from the lower seal mold, the upper seal portion configured to engage a counter-bore of a counter-bored nut for the lightning-protection fastener to reduce escape of energized particles; and

injecting a high-strength polymer into the tooling, to form the polymer seal integrally with the washer, wherein injecting the high-strength polymer into the tooling comprises injecting a high-strength polymer material into the lower seal mold and the upper seal mold to define the lower seal portion and the upper seal portion.

18. The method of claim 17 further comprising coating the washer with a dielectric material.

19. The method of claim 17 , wherein forming the washer comprises stamping the washer from sheet metal material.

20. The method of claim 17 , wherein the high-strength polymer comprises a polymer selected from the group consisting of:

polyamide-imide (PAI);

polyimide (PI);

polyaryletherketone (PAEK);

polyphenylene sulfide (PPS);

polyphenyl sulfone (PPSU); and

polyaryl ether sulfone (PAES).