International Aircraft Materials Fire Test Working Group Trump

International Aircraft Materials Fire Test Working Group Trump Taj Mahal Casino, Atlantic City, NJ March 1 -2, 2005 RANKING FLAMMABILITY OF AIRCRAFT MATERIALS USING MICROSCALE COMBUSTION CALORIMETRY Richard E. Lyon and Richard N. Walters* Fire Safety Branch AAR-440 FAA W. J. Hughes Technical Center Atlantic City International Airport, NJ 08405 *Galaxy Scientific Corporation, Egg Harbor Township, NJ WEB: www. fire. tc. faa. gov E-MAIL: Richard. E. Lyon@faa. gov

OUTLINE OF TALK RANKING FLAMMABILITY USING SMALL SCALE TEST Flammability • Ignition Resistance (0 , 90 , 60 , 45 Bunsen burner) • Fire Behavior (OSU, seat cushion test, radiant panel) Microscale Combustion Calorimetry • Operation and Theory • Comparison of Results for Hidden Materials • Heat Release Rate (OSU) • Bunsen Burner tests • Smoke Density • Radiant Panel • 1/4 -scale tests

FAA FLAMMABILITY TESTS Bunsen Burner Tests OSU HRR Test Seat Cushion Oil Burner Test Radiant Panel Test

SCALES OF FLAMMABILITY TESTING Microscale Combustion Calorimetry Milligram Flame Tests Fire Tests Bench-Scale Gram Kilogram SAMPLE SIZE Component-Scale Metric Ton

STEADY BURNING: Nylon 6 data 2000 Heat Release Rate, k. W/m 2 PA 6 . HRR = HRP q net 1500 . Slopes = HRP 1000 HRR 0 500 (k. W/m 2) HRP Intercepts = HRR 0 0 20 40 60 230 148 80 Ignitability 14 21 100 External Heat Flux, k. W/m 2 = HRR 0 + HRP q ext 120 Fire Response

IGNITABILITY: UL 94 vs. HRR 0 41 polymers, blends, and composites. UL 94 Rating HB V 2 Self-Extinguishing Self-Propagating V 1 V 0 -400 -200 0 200 400 600 HRR 0, k. W/m 2 (in cone calorimeter)

HEAT RELEASE RATE AND HEAT RELEAE CAPACITY The Heat Release Capacity (HRC), is related to the heat release rate (HRR) in flaming combustion c = Flaming combustion efficiency = Density = Pyrolysis depth = Surface heating rate 50 k. W/m 2 HDPE 1500 ABS 1000 PA 66 PP PMMA HIPS 2 HRC 2000 Peak HRR, k. W/m 2 HRR = ( ) HRC 500 PET PC POM PVC PVDF FEP PPS PEI 0 0 500 R = 0. 93 1000 1500 2000 Heat Release Capacity, J/g-K

HEAT RELEASE CAPACITY AND FLAMMABILITY IGNITABILITY Self extinguishing when: HRR 0 HRR* = HRC* HEAT RELEASE RATE For a particular heat flux (e. g. , 3. 5 W/cm 2): HRR HRC*

MEASURING HEAT RELEASE CAPACITY Gas Scrubber O 2 Meter Gas Flowmeter Exhaust Combustion O 2 Pyrolysis DAQ N 2 Sample Flaming Combustion Pyrolysis-Combustion Flow Calorimetry (PCFC)

FLAMMABILITY TESTING OF MILLIGRAM SAMPLES FAA/Galaxy Invention TGA Combustion Accessory Stand Alone Device

HEAT RELEASE CAPACITY FROM PCFC 260 W/g = 1 K/s

PCFC DATA & FIRE TESTS Relevant FAA Flammability Test Combustion Calorimetry Data Heat Release Rate (W/g) 500 PMMA 400 300 200 100 0 250 300 350 400 Burning Rate • OSU HRR • Bunsen Burner Ignition • Radiant Panel • Oil Burner Seat Test Heat of Combustion • Oxygen Bomb Calorimeter Ignition Temperature • Setchkins Furnace • Glow Wire Ignition 450 Temperature (°C) 500 550

IGNITION RESISTANCE (UL 94) AND HRC UL 94 Rating Halogen containing Flammability HB V 2 V 1 V 0 10 1000 10, 000 Heat Release Capacity, J/g-K

Limiting Oxygen Index (LOI), %O 2 IGNITION RESISTANCE (LOI) AND HRC 100 Halogen containing 80 60 40 20 0 10 1000 10, 000 Heat Release Capacity, J/g-K

12 SECOND VERTICAL BURN TEST AND HRC 10 10 Hidden Materials 8 Burn Length (cm) 6 6 4 4 2 2 0 0 0 100 200 300 400 HRC (J/g-K) 500 -2 600 Burn Time (seconds) 8

FIRE (HRP) AND MATERIAL (HRC) PROPERTIES HEAT RELEASE PARAMETER 100 Engineering Plastics Commodity Plastics Hidden Area Components HRP = q net HRC 10 cp Slope should be relatively constant for plastics for well-ventilated burning 1 10 1000 HRC (J/g-K) 104

HRR (OSU PEAK) AND HRC 350 OSU Peak HRR, k. W/m 2 300 Engineering Thermoplastics (0. 060 inch sheet) 250 200 150 100 50 R = 0. 72 0 0 100 200 300 400 500 600 Heat Release Capacity, J/g-K 700

NBS SMOKE DENSITY AND HRC 1000 Hidden Materials Smoke Density, D s 100 10 1 0. 01 0 100 200 300 400 HRC (J/g-K) 500 600

RADIANT PANEL TEST AND HRC 25 BURN TIME, seconds Hidden Materials 20 15 10 5 0 0 100 200 300 400 HRC (J/g-K) 500 600

INTERMEDIATE SCALE TEST AND HRC TEMPERATURE RISE AND HRC OF INSULATION BAGS MPET (262 J/g-K) PET 3 (250 J/g-K) PET 00 (155 J/g-K) PET 1 (138 J/g-K) PVF 1 (120 J/g-K) PI-O (47 J/g-K) PUF block, Baseline

HIDDEN MATERIALS: Accident Investigation Metalized Mylar Bag Hook & Loop (married) Cockpit Headliner F L A M M A B L E GRP Duct Plastic Conduit Ceiling Panel (back) Flexside Duct Pass OSU HRR Ceiling Panel (face) Silicone Rubber Pass Bunsen Burner Foam Core Duct 0 Swiss. Air 111 Database 50 100 150 HRC (J/g-K) 200 250

FLAMMABILITY (HRC) RANKING BY COST Flammability (J/g-K) 1000 PP Common Plastics PE ABS PS PPO NYLON 66 Epoxy PU Polyarylate PET PMMA Polysulfone PC PVC (rigid) PVF (TEDLAR) PES POM PPS 100 Phenolic PEI PEEK PEK LCP's PPSF Flammable PAI Specialty Plastics Current Aircraft (KAPTON) PI 10 Resin Plastic FAA Goal FAA Research Plastics 0. 1 1 10 Price of Plastic ($/lb) 100

CONCLUSIONS Heat release capacity HRC is a qualitative predictor of fire performance and flammability of aircraft materials Swelling, dripping, and barrier formation influence flame/fire tests but do not effect HRC.