Interlaboratory Study of Radiant Panel Test for Measuring

Inter-laboratory Study of Radiant Panel Test for Measuring Flammability of Thermal/Acoustic Insulation Materials Presented to: 8 th Triennial International Aircraft Fire and Cabin Safety Research Conference By: Steven Rehn Date: 10/26/2016 Federal Aviation Administration

Introduction • • • New Handbook chapter being written Need more data to finalize changes Industry dimension survey Round Robin Air Flow Study – Varied openings around the sliding platform to test how it affected air flow and material test results. – Future Work 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 2

Dimension Survey 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 3

Dimension Survey 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 4

Dimension Survey • Gaps around the drawer are the biggest difference between machines Open Area Around Drawer 350 300 Open Area (in 2) 250 200 150 100 50 0 A 10/26/2016 B C D E F G H I J K L M N O Lab Radiant Panel Insulation Test P Q R S T U V W X Y Z A 2 Federal Aviation Administration 5

Round Robin • Materials sent out to 28 labs (including FAA) • 24 Responses Received • 12 samples for each lab 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 6

18 18 16 16 14 14 12 12 10 10 8 8 6 6 4 4 2 2 0 0 A B C D E F G H I J K Flame Propagation 10/26/2016 L M Lab N After Flame Radiant Panel Insulation Test O P FP Fail Q R S T U V W X AF Fail Federal Aviation Administration 7 After Flame (seconds) Flame Propagation (inches) Metalized PEEK

7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 A B C D E F G H I J K Flame Propagation 10/26/2016 L M Lab N After Flame Radiant Panel Insulation Test O P FP Fail Q R S T U V W X AF Fail Federal Aviation Administration 8 After Flame (seconds) Flame Propagation (inches) Unmetalized PEEK

10 10 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 A B C D E F G H I J K Flame Propagation 10/26/2016 L M Lab N After Flame Radiant Panel Insulation Test O P FP Fail Q R S T U V W X AF Fail Federal Aviation Administration 9 After Flame (seconds) Flame Propagation (inches) Metalized PEEK w/ Tape

10 10 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 A B C D E F G H I J K Flame Propagation 10/26/2016 L M Lab N After Flame Radiant Panel Insulation Test O P FP Fail Q R S T U V W X AF Fail Federal Aviation Administration 10 After Flame (seconds) Flame Propagation (inches) Polyimide

Polyimide 1 -12 10/26/2016 13 -24 Radiant Panel Insulation Test Federal Aviation Administration 11

Polyimide FAA’s test result • Same test, completely different results. 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 12

Air Flow Study • New handbook has a larger drawer length compared to the current handbook. • This was done to allow less air to flow into the chamber during testing. • Larger drawer isn’t necessary – the openings around the drawer are what we need to standardize. • We ran some tests to see how changing the size of these openings affects calibration and test results. 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 13

Air Flow Study • Normal openings around the FAA’s radiant panel 10/26/2016 Left Right Front Back 5/16” 1/8” 0” 2. 25” Radiant Panel Insulation Test Federal Aviation Administration 14

Air Flow Study • Closed off left, rear, and right gaps 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 15

Air Flow Study • Gaps around the drawer fully open 2. 125” Left Gap 10/26/2016 Radiant Panel Insulation Test 1. 875” Right Gap Federal Aviation Administration 16

Air Flow Study Open w/ ~2” Gap on Each Side Open Area Around Drawer(in 2) 2. 09 123. 77 183. 44 Panel Set Point (°F) 1096 1105 1137 Heat Flux (BTU/ft 2 s) 1. 501 1. 502 1. 495 Chamber Temperature(°F) 381 366 425 Chimney Air Velocity (FPM) 205 260 278 Calibration vs. Drawer Openings 1150 290 1140 270 250 1130 230 1120 210 1110 190 1100 170 1090 150 0 50 100 150 Open Area Around Drawer (in 2) Panel Set Point 10/26/2016 Radiant Panel Insulation Test 200 Chimney Air Velocity Federal Aviation Administration 17 Chimney Air Velocity (ft/min) Normal Around Drawer Panel Set Point (°F) Closed Around Drawer

Air Flow Study • Openings Around Drawer: 2. 125” left, 1. 875” right, 2. 25 rear Set Point (°F) 1095 1110 1125 1137 Heat Flux (BTU/ft 2 s) 1. 398 1. 439 1. 495 Thermocouple (°F) 385 395 410 425 Chimney (FPM) 245 255 268 278 Under Right Side of Drawer (FPM) Under Left Side of Drawer (FPM) 90 65 91 60 95 65 Heat Flux (BTU/ft 2 s) 1. 481 1. 52 290 1. 5 285 1. 48 280 275 1. 46 270 1. 44 265 1. 42 260 1. 4 255 1. 38 250 1. 36 245 1. 34 1085 1095 1105 1115 1125 Panel Set Point (°F) Heat Flux 1135 Chimney Air Velocity (ft/min) Air Flow vs. Set Point 240 1145 Chimney Air Velocity • As the panel temperature increases, the air flow into the chamber increases causing you to need to increase the panel temperature further to compensate 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 18

Round Robin Data Set Point vs Open Area Around Drawer 1200 1180 1160 Panel Set Point (°F) 1140 1120 1100 1080 1060 1040 1020 1000 0 10/26/2016 50 100 150 200 Open Area (in 2) Radiant Panel Insulation Test 250 300 350 Federal Aviation Administration 19

Round Robin Data Panel Set Point vs. Chimney Velocity 400 350 Chimney Air Velocity (ft/min) Open Area vs. Chimney Velocity 300 250 200 150 100 50 0 0 50 10/26/2016 100 150 200 Open Area (in 2) 250 300 350 Radiant Panel Insulation Test 300 250 200 150 100 50 0 1000 1100 Panel Set Point (°F) Federal Aviation Administration 1200 20

Air Flow Study 12 12 12 10 10 8 8 6 6 4 4 2 2 0 0 1 Flame Prop 10/26/2016 2 3 Sample Number After Flame 4 5 FP Fail Flame Propagation (inches) 12 1 AF Fail Radiant Panel Insulation Test Flame Prop 2 3 Sample Number After Flame 4 After Flame (seconds) Gaps Open - Metalized PEEK After Flame (seconds) Flame Propagation (inches) Gaps Closed - Metalized PEEK 5 FP Fail Federal Aviation Administration AF Fail 21

Air Flow Study 4 4 4 3 3 2. 5 2 2 1. 5 1 1 0. 5 0 0 1 Flame Prop 10/26/2016 2 3 Sample Number After Flame 4 5 FP Fail 4 3. 5 Flame Propagation (inches) 3. 5 After Flame (seconds) 3. 5 Flame Propagation (inches) Gaps Open - Unmetalized PEEK 3. 5 3 3 2. 5 2 2 1. 5 1 1 0. 5 0 0 1 AF Fail Radiant Panel Insulation Test After Flame (seconds) Gaps Closed - Unmetalized PEEK Flame Prop 2 3 Sample Number After Flame 4 5 FP Fail Federal Aviation Administration AF Fail 22

Air Flow Study 4 4 4 3 3 2. 5 2 2 1. 5 1 1 0. 5 0 0 1 Flame Prop 10/26/2016 2 3 4 Sample Number After Flame 5 FP Fail 4 3. 5 6 Flame Propagation (inches) 3. 5 After Flame (seconds) 3. 5 Flame Propagation (inches) Gaps Open - Shrinking Material 3. 5 3 3 2. 5 2 2 1. 5 1 1 0. 5 0 0 1 AF Fail Radiant Panel Insulation Test After Flame (seconds) Gaps Closed - Shrinking Material Flame Prop 2 3 4 Sample Number After Flame 5 FP Fail Federal Aviation Administration 6 AF Fail 23

Air Flow Study 3. 5 4 3. 5 3 3 2. 5 2 2 1. 5 1 1 0. 5 0 0 1 Flame Prop 10/26/2016 2 3 Sample Number After Flame 4 5 FP Fail Flame Propagation (inches) 4 After Flame (seconds) Flame Propagation (inches) 4 Gaps Open - Metalized PEEK with Tape 4 3. 5 3 3 2. 5 2 2 1. 5 1 1 0. 5 0 0 1 AF Fail Radiant Panel Insulation Test After Flame (seconds) Gaps Closed - Metalized PEEK with Tape Flame Prop 2 3 Sample Number After Flame 4 5 FP Fail Federal Aviation Administration AF Fail 24

Air Flow Study • At the June meeting, we finalized plans to further study this issue • Continue conducting tests with 3 different air gap levels – Fully open – Partially open – Fully closed • Place array of thermocouples in the retaining frame to test how material temperature changes • Place smoke bomb below chamber to observe how the air travels through it • Additional material tests 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 25

Air Flow Study • Array of 15 thermocouples placed inside retaining frame • Tested at each air-gap configuration • Calibrated with calorimeter to 1. 5 Btu/ft 2 s each time • 3 tests with each configuration • Temperature averaged over 5 minutes 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 26

Air Flow Study 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 27

Air Flow Study 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 28

Air Flow Study 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 29

Intermediate Gaps Right: 0. 125” Left: 0. 3125” Rear: 2. 25” Front: 0” Set Point: 1113°F Chamber Temp: 370°F 10/26/2016 Fully Closed Right: 0” Left: 0” Rear: 0” Front: 0” Set Point: 1112°F Chamber Temp: 384°F Radiant Panel Insulation Test Fully Open Right: 1. 875” Left: 2. 125” Rear: 2. 25” Front: 0” Set Point: 1158°F Chamber Temp: 467°F Federal Aviation Administration 30

Air Flow Study Right Closed Right: 0. 125” Left: 2. 125” Rear: 2. 25” Front: 0” Set Point: 1113°F Chamber Temp: 369°F 10/26/2016 Radiant Panel Insulation Test Right Open Right: 1. 875” Left: 0” Rear: 0” Front: 0” Set Point: 1126°F Chamber Temp: 360°F Federal Aviation Administration 31

Future Work • Send thermocouple array to 3 other labs to test • Statistically determined that at least 20 samples of a material would be required at each air gap level to get the best results • 60 Metalized PEEK samples total for each lab 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 32

Questions? 10/26/2016 Radiant Panel Insulation Test Federal Aviation Administration 33