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Presented to: International Aircraft Materials FireTest Working Group, Atlantic City
By: Rich Lyon, AJP-6320
Date: October 21, 2009
Federal AviationAdministration
QUALIFICATION TEST FOR A/C
PANEL ADHESIVES
International Materials Fire Test Working Group
October 21, 20092Federal Aviation
Administration
Establish Establish similaritysimilarity of bonded details.of bonded details.
OBJECTIVEOBJECTIVEOBJECTIVE
PURPOSEPURPOSEPURPOSE
Develop a qualification testDevelop a qualification test for flammabilityfor flammabilityof adhesives used in bonded details.of adhesives used in bonded details.
APPLICATIONSAPPLICATIONSAPPLICATIONS
Certification of New PartsCertification of New Parts
International Materials Fire Test Working Group
October 21, 20093Federal Aviation
Administration
ADHESIVES TASK GROUPADHESIVES TASK GROUPADHESIVES TASK GROUP
3M3MAmerican AirlinesAmerican AirlinesBoeingBoeingBombardierBombardierBostikBostikC&D AerospaceC&D AerospaceDassaultDassaultFAAFAAHenkelHenkel
International Materials Fire Test Working Group
October 21, 20094Federal Aviation
Administration
INDUSTRY-PROPOSED METHODS OF COMPLIANCE FOR CERTIFICATION OF INTERIOR MATERIALS
INDUSTRYINDUSTRY--PROPOSED METHODS OF COMPLIANCE PROPOSED METHODS OF COMPLIANCE FOR CERTIFICATION OF INTERIOR MATERIALSFOR CERTIFICATION OF INTERIOR MATERIALS
BONDED BONDED DETAILSDETAILS2828
25.853(a)25.853(a)
Bunsen Burner Bunsen Burner SimilaritySimilarity
25.853(d)25.853(d)
Heat and Smoke Heat and Smoke SimilaritySimilarity
Testing detail Testing detail without without adhesive*adhesive* to Appendix to Appendix
F substantiates the F substantiates the bonded configurationbonded configuration
Test requiredTest required if: A > 2 ftif: A > 2 ft22
Possible Test if: 1 < A < 2 ftPossible Test if: 1 < A < 2 ft22
No test required* if: ANo test required* if: A < 1 ft< 1 ft22
Ref.Ref.No.No.
Feature / Feature / ConstructionConstruction
Part 2: Methods That Will Require Supporting Data
*For FAA Qualified Adhesives? *For*For FAA Qualified Adhesives? FAA Qualified Adhesives?
International Materials Fire Test Working Group
October 21, 20095Federal Aviation
Administration
ADHESIVE QUALIFICATION TEST ISSUESADHESIVE QUALIFICATION TEST ISSUESADHESIVE QUALIFICATION TEST ISSUES
FAR 25 versusFAR 25 versus Other Measurement MethodOther Measurement Method
Sample FormSample Form
Effect of Effect of AdherendsAdherends
Effect of Thickness: Effect of Thickness: Does thinner Does thinner substantiatesubstantiate thicker?thicker?
International Materials Fire Test Working Group
October 21, 20096Federal Aviation
Administration
-10
0
10
20
30
40
50
60
70
-10
0
10
20
30
40
50
60
70
Thickness, inches
Pea
k H
eat R
elea
se R
ate,
kW
/m2 T
otal Heat R
elease, kW-m
in/m2
Peak HRR
Total Heat ReleaseTotal Heat Release
0 .040 .080 0.12 0.16 0.20 0.24 0.28
EUROPLEX PPSU Clear
Example: Thermoplastic Thickness RangesExample: Thermoplastic Thickness RangesExample: Thermoplastic Thickness Ranges
OSU Peak HRR of 0.040″ does not substantiate .080″- 0.16″OSU OSU Peak Peak HRR HRR of 0.040of 0.040″″ doesdoes notnot substantiate .080substantiate .080″″-- 0.160.16″″
Proposed range
International Materials Fire Test Working Group
October 21, 20097Federal Aviation
Administration
Combustor
Pyrolyzer
Mixing Section
Sample Cup
Scrubber
Flow Meter
O2 Sensor
Exhaust
Purge Gas Inlet
Sample Post & Thermocouple
Oxygen Inlet
Standard Test Method for Measuring Flammability Properties of Plastics and Other Solid Materials Using Microscale Combustion Calorimetry, ASTM
D 7309
Standard Test Method for Measuring Flammability Properties of PlStandard Test Method for Measuring Flammability Properties of Plastics astics and Other Solid Materials Using Microscale Combustion Calorimetrand Other Solid Materials Using Microscale Combustion Calorimetry, ASTM y, ASTM
D 7309D 7309
International Materials Fire Test Working Group
October 21, 20098Federal Aviation
Administration
250 300 350 400 450 500 550
0
100
200
300
400
500 ηc
hc
Tp
Hea
t R
elea
se R
ate
(J/g
-K)
Temperature (°C)
μ Noncombustible Fraction (g/g)
800 850
THERMAL COMBUSTION PROPERTIES FROM MCC
THERMAL COMBUSTION PROPERTIES THERMAL COMBUSTION PROPERTIES FROM FROM MCCMCC
Peak Heat Release Rate =Heat Release Capacity (J/g-K)
Total Heat Release (J/g)
≈ Burning Temperature
International Materials Fire Test Working Group
October 21, 20099Federal Aviation
Administration
PP PE
PS
PET
ABSPMMA
Epoxy
POM
NYLON 66
PC
PPOPUPAR
PPSU
PPS PES
PEI LCP
PAI
PEKPEEK
0.1 1 10 100
Materials Cost* ($/lb)
Phenolic
KAPTON
1000
10
100PVF
Heat Heat Resistant Resistant PlasticsPlastics
PSU
PVC (rigid)
Commodity Commodity PlasticsPlastics
*Truckload Prices, 2001
Engineering Plastics
Hea
t R
elea
se C
apac
ity
(ηc)
, J/g
-K
TYPICALLY PASS FAAHRR TEST
TYPICALLY TYPICALLY PASS FAAPASS FAAHRR HRR TESTTEST
HEAT RELEASE CAPACITY VERSUS COST OF PLASTICS
HEAT RELEASE CAPACITY VERSUS HEAT RELEASE CAPACITY VERSUS COST OFCOST OF PLASTICSPLASTICS
International Materials Fire Test Working Group
October 21, 200910Federal Aviation
Administration
Pro
bab
ility
of
Pas
sin
g V
BB
, p
Heat Release Capacity ηc, J/g-K
η*= 448 J/g-Kn = 4.46R = 0.97
η*= 448 J/g-Kn = 4.46R = 0.97
ASTMASTMD 3801D 3801
VERTICAL BUNSEN BURNER TEST (114 plastics)VERTICAL BUNSEN BURNER TEST (114 plastics)VERTICAL BUNSEN BURNER TEST (114 plastics)Probability of Passing the UL 94 V-0 Requirement
0
0.2
0.4
0.6
0.8
1
0 200 400 600 800 1000 1200
p =1
1+ηc
η *
⎡
⎣ ⎢
⎤
⎦ ⎥
n
International Materials Fire Test Working Group
October 21, 200911Federal Aviation
Administration
HAND LAY-UP OF ADHESIVE / RESIN OSU SAMPLESHAND LAYHAND LAY--UP OF ADHESIVE / RESIN UP OF ADHESIVE / RESIN OSU OSU SAMPLESSAMPLES
• 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, 200912Federal Aviation
Administration
OSU TESTING OF ADHESIVE RESINSOSU OSU TESTING OF ADHESIVE RESINSTESTING OF ADHESIVE RESINS
BPA Epoxy
BPC Cyanate Ester
BPA Cyanate Ester
BPA Epoxy & MDA
BPC Epoxy
50 kW/m2
Silicone Resin
Time (minutes)
2-min HR
(kW-min/m2)
Peak HRR
(kW/m2)Resin
44111BPA Epoxy
2688BPAE + MDA
2872BPA CE
2848BPC Epoxy
1233Silicone Resin
1313BPC CE
International Materials Fire Test Working Group
October 21, 200913Federal Aviation
Administration
0
50
100
150
200
0 100 200 300 400 500 600 700
(R = 0.8264) pHRR = 6.4 ηc
avg
⟨pH
RR
⟩, kW
/m2
⟨ηc⟩, J/g-K
OSU PHRR (binned data) 101 RESINS AND PLASTICS)OSU PHRR OSU PHRR (binned data) 101 RESINS AND PLASTICS)(binned data) 101 RESINS AND PLASTICS)
Maximum Heat Release Capacity from Curve Fit
ηcmax =
656.4
⎛ ⎝ ⎜
⎞ ⎠ ⎟
2
= 103 J / g −K
International Materials Fire Test Working Group
October 21, 200914Federal Aviation
Administration
• HRR ≤ 65 kW/m2 = Pass = P
• HRR > 65 kW/m2 = Fail = F
pHRR19
101315222950
105108115120120121121127129136140141152153155156159173192196201203215215230235248261265276295298301316345349359
82559136631553054926149
1236052
109646569
1109030854572
10636327465
213150
97258
5544
188199
93211232166115207
90
127
174
254
355
36 9/10 = 0.90
6/10 = 0.60
3/10 = 0.30
4/10 = 0.40
0/10 = 0.00
ηcp = P/(P + F)⟨ηc⟩
Etc.
y
OSU Data for AIRCRAFT CABIN
MATERIALS
OSU OSU Data for Data for AIRCRAFT CABIN AIRCRAFT CABIN
MATERIALSMATERIALS
Transform Quantitative Data into Qualitative Data Using Pass/Fail�
Criterion
14 CFR 25.853
PPPPFPPPPFPPFPPFPPFFFPFPFFPPFPFFFFPPFFFFFFFFF
International Materials Fire Test Working Group
October 21, 200915Federal Aviation
Administration
Pro
bab
ility
of
Pas
sin
g O
SU
pH
RR
, p
η*= 140 J/g-Kn = 2.4
R = 0.97
Heat Release Capacity (ηc), J/g-K
η*= 140 J/g-Kn = 2.4
R = 0.97
14 CFR 2514 CFR 25
OSU PHRR (101 RESINS AND PLASTICS)OSU PHRR OSU PHRR (101 RESINS AND PLASTICS)(101 RESINS AND PLASTICS)Probability that pHRR ≤ 65 kW/m2
0
0.2
0.4
0.6
0.8
1
0 100 200 300 400 500 600 700
p =1
1+ηc
η *
⎡
⎣ ⎢
⎤
⎦ ⎥
n
ηc
max = η * 10.683
−1⎛
⎝ ⎜
⎞
⎠ ⎟
12.4
= 102= 102 J/gJ/g--KK
International Materials Fire Test Working Group
October 21, 200916Federal Aviation
Administration
AdhesiveAdhesive
PartPart
SubstrateSubstrate
ρρp p , , ηηpp
ρρa a , , ηηaa
ρρs s , , ηηss
ρρii = Areal Density of Layer = Areal Density of Layer ii, g/m, g/m22
ηηii = Heat Release Capacity of Layer in = Heat Release Capacity of Layer in MCC MCC ii, , J/gJ/g--KK
mmii = Mass Fraction of Layer = Mass Fraction of Layer ii = = ρρi i //ΣΣρρii
EFFECT OF ADHERENDS and THICKNESS (Additive Approach Using MCC Data)
EFFECT OF EFFECT OF ADHERENDS ADHERENDS and THICKNESS and THICKNESS (Additive Approach Using (Additive Approach Using MCC MCC Data)Data)
ηconstruction = mpηp + maηa + msηsηηconstructionconstruction = = mmppηηp p + m+ maaηηa a + m+ mssηηss
International Materials Fire Test Working Group
October 21, 200917Federal Aviation
Administration
AdhesiveAdhesive
PartPart
SubstrateSubstrate
TTii, , ρρ , h, hcc, E, A, etc., E, A, etc.
TTi i = = Thickness of Layer Thickness of Layer ii, cm, cmρρii = Density of Layer = Density of Layer ii, g/m, g/m33
hhii = Heat Release of Layer= Heat Release of Layer, , J/gJ/gEEi i , A, Aii == Thermal Decomposition KineticThermal Decomposition Kinetic Parameters of Parameters of ii
EFFECT OF ADHERENDS and THICKNESS (ThermaKin Numerical Burning Model)
EFFECT OF EFFECT OF ADHERENDS ADHERENDS and THICKNESS and THICKNESS (ThermaKin Numerical Burning Model)(ThermaKin Numerical Burning Model)
TTii, , ρρ , h, E, A, etc., h, E, A, etc.
TTii, , ρρ , h, E, A, etc., h, E, A, etc.
Transient energy and mass balance calculationTransient energy and mass balance calculationTransient energy and mass balance calculation
International Materials Fire Test Working Group
October 21, 200918Federal Aviation
Administration
OSU HRR OF BONDED CONSTRUCTION (ThermaKin Simulation)
OSU HRR OSU HRR OFOF BONDED CONSTRUCTION BONDED CONSTRUCTION (ThermaKin Simulation)(ThermaKin Simulation)
Heat Flux = 35 kW/m2
(OSU)
+
15 kW/m2
(Flame)
Heat Flux = Heat Flux = 35 kW/m35 kW/m22
((OSUOSU))
++
15 kW/m15 kW/m22
(Flame)(Flame)Adhesive Layer Adhesive Layer Thickness = Thickness = 0.2, 0.2,
0.5, 1 and 1.5 mm0.5, 1 and 1.5 mm
hhcc = 2X Substrate= 2X Substrate
Substrates =Substrates = 1/161/16″″ ((1.5 1.5 mm) Thick Charring mm) Thick Charring
Plastic Plastic (Polycarbonate)(Polycarbonate)
International Materials Fire Test Working Group
October 21, 200919Federal Aviation
Administration
0
0.2
0.4
0.6
0.8
1
0
0.2
0.4
0.6
0.8
1
0 1 2 3 4 5
1.5 mm Adhesive Layer1.5 mm Adhesive Layer1.5 mm Adhesive Layer
0
0.2
0.4
0.6
0.8
1
0
0.2
0.4
0.6
0.8
1
0 1 2 3 4 5
1 mm Adhesive Layer
1 mm Adhesive 1 mm Adhesive LayerLayer
0
0.2
0.4
0.6
0.8
1
0
0.2
0.4
0.6
0.8
1
0 1 2 3 4 5
0.5 mm Adhesive Layer0.5 mm Adhesive Layer0.5 mm Adhesive Layer
HR
R (
arbi
trar
y un
its)
HR
(arbitrary units)
Time, min
0
0.2
0.4
0.6
0.8
1
0
0.2
0.4
0.6
0.8
1
0 1 2 3 4 5
0.2 mm Adhesive Layer0.2 mm Adhesive Layer0.2 mm Adhesive Layer
Time, min
Time, minTime, min
OSU HRRs of BONDED CONSTRUCTIONS (ThermaKin)OSU OSU HRRsHRRs of BONDED CONSTRUCTIONS (ThermaKin)of BONDED CONSTRUCTIONS (ThermaKin)
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