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Presented to:
By:
Date:
Federal AviationAdministration
FAA 6th Triennial Cabin and Fire Safety
Conference
FAA Overview on Testing of Magnesium Alloys for Use
in an Aircraft Cabin
Triennial Conference, Atlantic City
Tim Marker, FAA Technical Center
October 27, 2010
2 2Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Key Activities
Initial Policy Statement
IAMFTWG
Discuss Threats
SAE Seat Committee
Potential Areas of Use
Test Based on Threat
FAA Policy and Rulemaking
AS8049 rev A review
Initial Lab-Scale Testing
Full-Scale Testing
Lab-Scale Test Development
Final FAA Policy
3 3Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Use of Magnesium in Airplane Cabins—Updated 10/07
The FAA has had several recent inquiries regarding the use of magnesium in airplane cabins. Specifically, magnesium alloys have been suggested as substitute for aluminum alloys in seat structure, as well as other applications, due to the potential for weight savings.
The FAA’s central concern regarding the use of magnesium in the cabin is flammability. The current regulations do not address the potential for a flammable metal to be used in large quantities in the cabin. Therefore, if such a material were introduced to the cabin, the FAA would have to be convinced that the level of safety was not reduced. Special conditions may be required to establish appropriate criteria. Different magnesium alloys have different susceptibility to ignition, however, magnesium remains a material that, once ignited, is very challenging to cope with using fire extinguishers currently available on aircraft.
The use of magnesium is currently the subject of a task group of the International Aircraft Materials Fire Test Working Group. Depending on the outcome of the task group’s work, the FAA may support additional research in this area, to the extent industry can supply materials. This would likely include full-scale testing should the initial assessments suggest there is some potential for acceptable installations. Both the post crash, as well as in-flight, fire scenarios need to be addressed.
FAA Policy Statement
4 4Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Key Activities
Initial Policy Statement
IAMFTWG
Discuss Threats
SAE Seat Committee
Potential Areas of Use
Test Based on Threat
FAA Policy and Rulemaking
AS8049 rev A review
Initial Lab-Scale Testing
Full-Scale Testing
Lab-Scale Test Development
Final FAA Policy
5 5Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
International Aircraft MaterialsFire Test Working Group
Issues and concerns in the area of aircraft materials fire safety testing are discussedwith emphasis on the current test methods.
The WG is open to anyone in the international community, including industry,government, and academia with an interest in aircraft materials fire safety and testing
Meets three times per year…
One meeting held in Atlantic City, New Jersey
One meeting held at host organization in North America
One meeting held at host organization outside the US
6 6Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Key Activities
Initial Policy Statement
IAMFTWG
Discuss Threats
SAE Seat Committee
Potential Areas of Use
Test Based on Threat
FAA Policy and Rulemaking
AS8049 rev A review
Initial Lab-Scale Testing
Full-Scale Testing
Lab-Scale Test Development
Final FAA Policy
7 7Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
SAE Aircraft Seat Committee
SAE International Aerospace Standard – AS8049 rev A“Performance Standard for Seats in Civil Rotorcraft, Transport Aircraft
and General Aviation”
Para 3.3.3 states, “Magnesium alloys shall not be used.”
SAE Aircraft Seat Committee: Custodian of Standard AS8049
FAA – TSO-C127, Rotorcraft and Transport Airplane Seating SystemsReferences AS8049
8 8Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Key Activities
Initial Policy Statement
IAMFTWG
Discuss Threats
SAE Seat Committee
Potential Areas of Use
Test Based on Threat
FAA Policy and Rulemaking
AS8049 rev A review
Initial Lab-Scale Testing
Full-Scale Testing
Lab-Scale Test Development
Final FAA Policy
9 9Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Initial Laboratory-Scale Testing
10 10Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Method: Conduct baseline tests using OEM aluminum-framed triple seats. Tests will simulate apost-crash fire with fuselage rupture, allowing external fire to directly impact the cabin materials.
Then…
Conduct additional tests in an identical fashion using mag-alloy in the construction of theprimary seat components. External fire permitted to burn for 5 minutes, then internal firepermitted to burn for 5 additional minutes before applying water.
Outcome: Determine if the use of mag-alloy poses additional hazard during the 10-minute event
Full-Scale Testing
11 11Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Primary Seat Components
Spreader
Cross Tube
Leg
12 12Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Full-Scale Testing
13 13Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Full-Scale Test Apparatus
14 14Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Foam supplied by Chestnut Ridge
Seat-back frame built in house
Dress covers supplied by Preferred Aviation, Miami
Aluminum front pan
OEM Coach Style Seats w/Modified Back Frame
15 15Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Baseline Test Configuration
16 16Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Application of Water Post-Testwater applied at end of all tests (not just magnesium), for similarity
17 17Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Baseline Test Result
18 18Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Baseline Test Result
19 19Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Baseline Test Result
melting of primary leg component
melting of crosstube component
20 20Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Baseline Test Summary
Incapacitation reached in 4 min 10 sec at forward location
Pan fire extinguished at 5 minutes using AFFF
Seat bottom cushions on port side heavily involved in fire
Increased melting of primary seat structure compared to previousbaseline tests
Seat backs (cushions, covers, plastics) mostly consumed on port side;largely intact on starboard side
Interior fire extinguished at 10 minutes using water
21 21Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Mag-Alloy Full-Scale Testing
•WE-43 (good-performing material)
•AZ-31 (poor-performing material)
•WE-43 in primary + back frame + baggage bar
•WE-43 in primary + back frame + baggage bar (repeat)
22 22Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 Test Configuration
23 23Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 Test Configuration
24 24Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 Test Results
25 25Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 Test ResultSummary of Findings
Incapacitation reached in 4 min 38 sec at forward location
Pan fire extinguished at 5 minutes using AFFF
Seat bottom cushions on port side heavily involved in fire
Increased melting of primary seat structure compared to baseline 3 test
Seat backs (cushions, covers, plastics) mostly consumed on port side;largely intact on starboard side
Interior fire extinguished at 10 minutes using water
26 26Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
AZ-31 Test Configuration
27 27Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
AZ-31 Test Results
28 28Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
AZ-31 Test ResultSummary of Findings
Incapacitation reached in 4 min 33 sec at forward location
Pan fire extinguished at 5 minutes using AFFF
Seat bottom cushions on port side heavily involved in fire
Increased melting of primary seat structure compared to baseline 3 test
Seat backs (cushions, covers, plastics) mostly consumed on port side;largely intact on starboard side
Interior fire extinguished at 10 minutes using water
29 29Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Test ComparisonTemperature 4' to 5' in Forward Cabin
0
100
200
300
400
500
600
0 60 120 180 240 300 360 420 480 540 600 660
Time (seconds)
Tem
pera
ture
(o F)
BL3 FWD Tree 4'BL3 FWD Tree 5'WE-43 FWD Tree 4'WE-43 FWD Tree 5'AZ-31 FWD Tree 4'AZ-31 FWD Tree 5'
Pan
Ext
ingu
ishe
d
Cab
in E
xtin
guis
hed
30 30Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Cabin Survivability Comparison
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 60 120 180 240 300
Time (Seconds)
Frac
tiona
l Effe
ctiv
e D
ose
FED Fwd 66" (Baseline)FED Mid 66" (Baseline)FED Fwd 66" (WE-43)FED Mid 66" (WE-43)FED Fwd 66" (AZ-31)FED Mid 66" (AZ-31)
169 sec148 sec 278 sec250 sec
31 31Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 All-Mag Test
32 32Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 All-Mag Test
33 33Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
WE-43 All-Mag Test
34 34Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
All-Mag Repeat Test
35 35Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
All-Mag Repeat Test
36 36Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
All-Mag Repeat Test
37 37Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Summary of Full-Scale Testing
Incapacitation results very similar for baseline and mag-alloy tests
Noticeable difficulty extinguishing burning mag-alloy during AZ-31 test
Slight flashing of burning mag-alloy during water application for WE-43 test
For baseline and mag-alloy tests, pan fire extinguished at 5 min, water applied at 10
•slightly better for mag-alloys at forward location
•slightly worse for mag-alloys at mid location
•More severe fire condition caused more rapid incapacitation during
“all-mag” tests
38 38Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Future Considerations
All full-scale test results would help define an appropriatelab-scale test method or methods, which is the primarygoal of the research.
Although post crash full-scale test results will help in determining the safe application of magnesium in seat frames, other scenarios and testing will also be used.
If magnesium alloys are determined safe for use in seat frames, a representative lab test/tests will be developed.
39 39Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Development of a Lab-Scale Test
40 40Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Items to Consider…
Thermal Insult•Duration•Size•Intensity
Test Sample•Size•Geometry•Orientation
Test Parameters•Melting Time
•After Flame Time•Weight Loss?
Development of a Lab-Scale Test
41 41Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010
Sample failNo
Ignition of sample ended within 15 seconds?
Yes
Continue burner exposure until ignition occurs
Once ignition occurs, continue burner exposure for an additional 30 seconds
Does sample ignite in less than 2 minutes?
Expose x by x by x test sample to burner
Sample pass
Ignition after 10 minutes exposure?
Burner off
Yes No
Yes NoSample pass Sample fail
Possible Lab-Scale Test Structure
42 42Federal AviationAdministration
FAA Overview on Testing of Magnesium AlloysOctober 27, 2010