Federal Aviation Administration QUALIFICATION TEST FOR AC PANEL

Federal Aviation Administration QUALIFICATION TEST FOR A/C PANEL ADHESIVES Presented to: International Aircraft Materials Fire Test Working Group, Atlantic City By: Rich Lyon, AJP-6320 Date: October 21, 2009

OBJECTIVE Develop a qualification test for flammability of adhesives used in bonded details. PURPOSE Establish similarity of bonded details. APPLICATIONS Certification of New Parts International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 2

ADHESIVES TASK GROUP 3 M American Airlines Boeing Bombardier Bostik C&D Aerospace Dassault FAA Henkel International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 3

INDUSTRY-PROPOSED METHODS OF COMPLIANCE FOR CERTIFICATION OF INTERIOR MATERIALS Part 2: Methods That Will Require Supporting Data Ref. No. 28 Feature / Construction BONDED DETAILS 25. 853(a) 25. 853(d) Bunsen Burner Similarity Heat and Smoke Similarity Testing detail without adhesive* to Appendix F substantiates the bonded configuration Test required if: A > 2 ft 2 Possible Test if: 1 < A < 2 ft 2 No test required* if: A < 1 ft 2 *For FAA Qualified Adhesives? International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 4

ADHESIVE QUALIFICATION TEST ISSUES FAR 25 versus Other Measurement Method Sample Form Effect of Adherends Effect of Thickness: International Materials Fire Test Working Group October 21, 2009 Does thinner substantiate thicker? Federal Aviation Administration 5

70 70 60 60 50 Proposed range 40 Peak HRR 50 40 30 30 20 20 Total Heat Release 10 0 EUROPLEX PPSU Clear -10 0 . 040 -10. 080 0. 12 0. 16 0. 20 0. 24 0. 28 Thickness, inches Total Heat Release, k. W-min/m 2 Peak Heat Release Rate, k. W/m 2 Example: Thermoplastic Thickness Ranges OSU Peak HRR of 0. 040 does not substantiate. 080 - 0. 16 International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 6

Standard Test Method for Measuring Flammability Properties of Plastics and Other Solid Materials Using Microscale Combustion Calorimetry, ASTM D 7309 Oxygen Inlet Combustor Mixing Section Pyrolyzer Scrubber Flow Meter O 2 Sensor Exhaust Sample Cup Purge Gas Inlet Sample Post & Thermocouple International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 7

Heat Release Rate (J/g-K) THERMAL COMBUSTION PROPERTIES FROM MCC 500 Peak Heat Release Rate = Heat Release Capacity (J/g-K) c 400 hc Total Heat Release (J/g) 300 Tp 200 Burning Temperature 100 Noncombustible Fraction (g/g) 0 250 300 350 400 450 500 550 800 850 Temperature (°C) International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 8

Heat Release Capacity ( c), J/g-K HEAT RELEASE CAPACITY VERSUS COST OF PLASTICS 1000 PP PMMA ABS PS NYLON 66 Epoxy PU PET PAR PPO PSU POM PC PVC PPS PES (rigid) Phenolic PEI 100 TYPICALLY PASS FAA HRR TEST 10 0. 1 Commodity Plastics PE 1 Engineering Plastics PVF PEEK PEK LCP Heat Resistant Plastics PPSU PAI KAPTON 10 100 Materials Cost* ($/lb) *Truckload Prices, 2001 International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 9

VERTICAL BUNSEN BURNER TEST (114 plastics) Probability of Passing VBB, p Probability of Passing the UL 94 V-0 Requirement 1 ASTM D 3801 0. 8 0. 6 0. 4 0. 2 *= 448 J/g-K 0 0 200 400 600 800 Heat Release Capacity International Materials Fire Test Working Group October 21, 2009 1000 c, J/g-K 1200 n = 4. 46 R = 0. 97 Federal Aviation Administration 10

HAND LAY-UP OF ADHESIVE / RESIN OSU SAMPLES • • Fiberglass-reinforced adhesive samples are made by hand lay-up. Samples cured between two Teflon-coated aluminum plates in heated press. Cured samples trimmed to 6 x 6 for OSU HRR testing. Resulting samples ~ 40% resin by weight. International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 11

OSU TESTING OF ADHESIVE RESINS Resin Peak 2 -min HRR HR (k. W/m 2) (k. W-min/m 2) BPA Epoxy 111 BPAE + MDA 88 BPA CE 72 BPC Epoxy 48 Silicone Resin 33 BPC CE 13 International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 44 26 28 28 12 13 12

OSU PHRR (binned data) 101 RESINS AND PLASTICS) Maximum Heat Release Capacity from Curve Fit avg p. HRR , k. W/m 2 200 (R = 0. 8264) 150 100 50 0 0 100 200 300 400 500 600 700 c , J/g-K International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 13

c 36 127 174 254 355 c p. HRR y 1 9 10 13 15 22 29 50 105 108 115 120 121 127 129 136 140 141 152 153 155 156 159 173 192 196 201 203 215 230 235 248 261 265 276 295 298 301 316 345 349 359 8 25 59 13 66 31 55 30 54 92 61 49 123 60 52 109 64 65 69 110 90 30 85 45 72 106 36 32 74 65 213 150 97 258 55 44 188 199 93 211 232 166 115 207 90 P P P P F P P F F F P P F F F F P P F F F F F p = P/(P + F) 9/10 = 0. 90 6/10 = 0. 60 Transform Quantitative Data into Qualitative Data Using Pass/Fail� Criterion 3/10 = 0. 30 14 CFR 25. 853 4/10 = 0. 40 • HRR 65 k. W/m 2 = Pass = P • HRR > 65 k. W/m 2 = Fail = F 0/10 = 0. 00 Etc. Fire Test Working Group International Materials October 21, 2009 OSU Data for AIRCRAFT CABIN MATERIALS Federal Aviation Administration 14

Probability of Passing OSU p. HRR, p OSU PHRR (101 RESINS AND PLASTICS) Probability that p. HRR 65 k. W/m 2 14 CFR 25 1 0. 8 0. 6 0. 4 = 102 J/g-K 0. 2 *= 140 J/g-K n = 2. 4 R = 0. 97 0 0 100 200 300 400 500 600 700 Heat Release Capacity ( c), J/g-K International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 15

EFFECT OF ADHERENDS and THICKNESS (Additive Approach Using MCC Data) construction = mp p + ma a + ms s Part Adhesive Substrate p , p a , a s , s i = Areal Density of Layer i, g/m 2 i = Heat Release Capacity of Layer in MCC i, J/g-K mi = Mass Fraction of Layer i = i / i International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 16

EFFECT OF ADHERENDS and THICKNESS (Therma. Kin Numerical Burning Model) Transient energy and mass balance calculation Ti, , hc, E, A, etc. Part Ti, , h, E, A, etc. Adhesive Ti, , h, E, A, etc. Substrate Ti = Thickness of Layer i, cm i = Density of Layer i, g/m 3 hi = Heat Release of Layer, J/g Ei , Ai = Thermal Decomposition Kinetic Parameters of i International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 17

OSU HRR OF BONDED CONSTRUCTION (Therma. Kin Simulation) Heat Flux = 35 k. W/m 2 (OSU) + 15 k. W/m 2 (Flame) Substrates = 1/16 (1. 5 mm) Thick Charring Plastic (Polycarbonate) Adhesive Layer Thickness = 0. 2, 0. 5, 1 and 1. 5 mm hc = 2 X Substrate International Materials Fire Test Working Group October 21, 2009 Federal Aviation Administration 18

OSU HRRs of BONDED CONSTRUCTIONS (Therma. Kin) 1 1 1 0. 2 mm Adhesive Layer 0. 8 0. 6 0. 4 0. 2 0 0 1 2 3 Time, min 4 1 mm Adhesive Layer 0. 5 mm Adhesive Layer 0. 8 0. 6 0. 4 0. 2 0 0 1 1 5 1 HR (arbitrary units) HRR (arbitrary units) 1 0 1 2 3 Time, min 4 5 0 1 1. 5 mm Adhesive Layer 0. 8 0. 6 0. 4 0. 2 0. 8 0 0 1 2 3 Time, min 4 5 International Materials Fire Test Working Group October 21, 2009 0 0 0 1 2 3 Time, min 4 Federal Aviation Administration 5 0 19