INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST WORKING … · 11.5 13.3 13.9 14.7 15.6 21.0 23.9 29.5 40.0 40.0 40.0 40.0 40.0 0 10 20 30 40 50 60 F R FF H O AE P A E S L M W Q Y AA I

INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST WORKING GROUPATLANTA, GEORGIA OCTOBER 19-20, 2005 MEETING WJH FAA Technical CenterJohn W. ReinhardtFire Safety Section, AAR-422 Atlantic City Int’l Airport, New Jersey 08405

TOPICSProject Objectives

Brief Overview (London Meeting)

Answer to Previous TG Questions

Discuss Tests Result Data

Discuss Intermediate-Scale Test vs Radiant Panel Test





Discuss Intermediate-Scale Test vsRadiant Panel Test

OBJECTIVESFAA's goal is to raise the standard

for the airplane such that fires in inaccessible areas do not spread and create catastrophic conditions.

For ducts, the current test does not predict the behavior of the part in actual conditions and therefore suggests the need for a new standard.






BRIEF OVERVIEWDuring our last meeting in Gatwick, UK (June 28-29, 2005) the following was discussed:

The fire test results of some (10) aircraft duct materials were presented.

An approach to a new fire test protocol (based on the current FAA radiant panel test) was presented as a possible means of compliance to current regulations.

First task group meeting was conducted.

All of the task group members agreed that the 12-seconds vertical Bunsen burner test is not a good discriminator to determine the fireworthiness of a material.

A couple of members did not agree that the current FAR test protocol should be evaluated under the current venue (recommended use of ARAC Committee).






PREVIOUS TASK GROUP MEMBERS QUESTIONSQ1. “But, as an industry task group member, it is not clear to me that there has been enough industry discussion about the need for a new test requirement that takes into account in-service history relative to ducting.”

A1: As mentioned in the Objective section, the current FAA’s mission is to raise the standard for the airplane such that fires in inaccessible areas do not spread and create catastrophic conditions. During the evaluation of the current test protocol for aircraft ducting, it was determined that this existing test is not up to par with the FAA’s mission (Internal Deficiency). The FAA safety strategy today is to be proactive rather than reactive as in the past.

Accident Date: 9/5/96, Location: Newburgh, New York Operator: Federal Express, Cause: Unknown Fire Source in Cargo

Accident Date: 9/4/93, Location: Santo Domingo, Dominican Republic Operator: Dominicana, Cause: Unknown Fire aft of lavatory

PREVIOUS TASK GROUP MEMBERS QUESTIONS (CONT.)Q2: “Prioritization of this effort relative to other safety improvements should also be discussed, particularly with FAR 25.856(a) [Thermal/Acoustic Insulation Materials] now in effect.”

A2: When compared to FAR 25.856(a), this is a low priority project.

PREVIOUS TASK GROUP MEMBERS QUESTIONS (CONT.)Q3: “Having well defined goals along with the supporting rationale will provide a fundamental basis for the Ducting Task Group activities.”

A3: Ducting components are major parts in the aircraft, running in the attic, cheek, cargo compartments, and other areas, that have the probability of becoming a fuel source during a fire. Since this ducting system interconnects along the aircraft, it may provide a propagation path to the fire. To evaluate the propagation characteristic of a ducting material, the FAA requires that it be tested according to Appendix F to Part 25, Part I (a) (ii). After re-evaluating the Appendix F test, commonly known as the 12-seconds Vertical Bunsen Burner, results show that this test does not predict the behavior of the part in actual conditions and therefore suggests the need for a new test standard.

12-sec Vertical Bunsen Burner Test Intermediate-Scale Test






TESTS RESULT DATA

12 & 60-Sec Vertical Bunsen Burner Test

Intermediate-Scale Test Radiant Panel Test

OSU Heat Release Test NBS Smoke Test Micro-Scale Combustion Calorimeter Test

TESTS RESULT DATA (CONT.)

• About 33 different types of specimens were donated by the working group members and tested by the FAATC (included different materials, shapes, configuration, thickness)

Rigid Ducts

Flexible Ducts

Thermoplastic & Thermosetting Composites

Old and New Materials Used for Aircraft Ducting

• More than 550 tests were conducted

12 & 60 SECONDS VERTICAL BUNSEN BURNER TESTS:Test Protocol: Chapter 1 of DOT/FAA/CT-89/15 Aircraft Material Fire Test Handbook

Sample Size: 75mm x 305mm

Heat Source: Methane Flame (41 kW/m2, 925 ºC)

Heat Source Exposure: 12 (60) seconds

Flame Extinguishing Time: <15 seconds

Burn Length: <20.32cm (<15 cm)

Drip Extinguishing Time: <5 seconds

12-SECONDS VERTICAL BUNSEN BURNER TEST Aircraft Ducting Materials

0.3

1.2 1.31.8 2.0 2.3 2.4

2.8 2.93.4

3.7 4.0 4.0 4.34.8 4.9 5.1

5.55.9 6.0

6.46.9

7.2

8.0

13.8 13.9

0

2

4

6

8

10

12

14

16

18

20

R X E K U Z Y P I H T S Q O N M J A W B L V C F D G

Material

Bur

n Le

ngth

(cm

)

FAA Requirement: L < 20.32 cm


0.0 0.0 0.0 0.0 0.0 0.00.3

0.71.0 1.0 1.0 1.0 1.0 1.0 1.2 1.4 1.6

1.9 2.02.3

2.73.0

4.0 4.2

5.0

9.4

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

E F G O R U Y I A B D H N S P X T Q J M C W L V K Z

Material

Flam

e Ex

tingu

ishi

ng T

ime

(sec

)

FAA Requirement: t < 15 seconds

Drip Flame Time = 0 sec for All Materials


1.5

3.3 3.33.8

5.1 5.2

6.9 7.0

8.59.0 9.2 9.5

10.5 10.8 11.2 11.5 11.612.4

12.9

14.5 14.8 15.215.7 15.9

16.4

20.4

0

5

10

15

20

25

R U T E P X O Z K I C F A Q Y AA N S V W M D AB G J H

Material

Bur

n Le

ngth

(cm

)

FAA Requirement: L < 15 cm


0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

3.5

6.8

22.5

0

3

6

9

12

15

18

21

24

A AA AB C D E F G H J K L M N O P Q R S T U V W Z I Y X

Material

Flam

e Ex

tingu

ishi

ng T

ime

(sec

)

FAA Requirement: t < 15 sec

Drip Flame Time = 0 sec for All Materials

INTERMEDIATE-SCALE FIRE TEST:

Test Protocol: FAA Report DOT/FAA/AR-99/44 - Dev. Of Improved Flammability Criteria for Aircraft Thermal Acoustic Insulation

Sample Size: 15.2cm (30.4cm) x 243.8cm

Heat Source: Polyurethane Foam Block (49 kW/m2, 781 ºC)

Heat Source Exposure: ~6 minutes

Not a compliance test

INTERMEDIATE-SCALE FIRE TESTAircraft Ducting Materials / Narrow-Body Configuration

18.729.2 34.8 35.2 35.6 36.1

43.3 47.0 47.3 48.9 51.4 51.8 52.7 53.0 54.0

74.1

131.4

304.8

0

50

100

150

200

250

300

350

AD M X P Q R O V T F K W H N Y B D C

Material

Bur

ned

Leng

th (c

m)

Radiant Panel Max Burned Length < 5.08 cm

Ignition Source Outside


92 113

302347 374

510593 610 632 644 653

690750 761

1081 11121190

1752

32583

0

200

400

600

800

1000

1200

1400

1600

1800

2000

AD F X P M O W V H Y T Q K R U B G N C

Material

Bur

ned

Are

a (c

m2 )



512

562

641 655

697 708

756 758777 779 787 797 804 816 816 825 825 834

896

0

100

200

300

400

500

600

700

800

900

1000

W H G B F N R Q T U X P Y V M C O AD K

Material

Tem

pera

ture

(deg

C)



5054

5658 58 58 59 59

6265 65 66 66

70 7074

7781

92

0

10

20

30

40

50

60

70

80

90

100

F Q W V M T N X Y R U O P AD H G B K C

Material

Hea

t Flu

x (k

W/m

2 )


Narrow-Body Configuration: Ignition Source Outside

Large Duct IST Test

Material D & E

Material BMaterial B

Narrow-Body Configuration: Ignition Source Inside

Narrow-Body Configuration: Ignition Inside

Wide-Body Configuration: Ignition Outside

Material D

Material D

Material B

Material B

Narrow-Body Configuration: Ignition Inside

Wide-Body Configuration: Ignition In-Outside

INTERMEDIATE-SCALE TEST (CONT.)The narrow-body test configuration was more

severe than the wide-body test configuration (heat confined)

The narrow-body configuration with the ignition source inside the duct was more severe that with the ignition source next to the duct outside (more heat from conduction, convection and radiation sources).

Wide-body Test Configuration

Narrow-body Test Configuration

RADIANT PANEL TEST:Test Protocol: Appendix F to Part 25 (Part IV) – Test Method To Determine the Flammability and Flame Propagation Characteristics of Thermal/Acoustic Insulation Materials


Heat Source: Propane Flame & Radiant Heating Coils (17 kW/m2 panel, 147 kW/m2 pilot)

Heat Source Exposure: 15 seconds (pilot) and until flames are extinguished (radiant panel)

Max Flame Propagation: < 5.08 cm

Max Flame Time: < 3 seconds

RADIANT PANEL TEST RESULTS Aircraft Ducting Materials

1.41.9 2.0 2.2 2.3 2.5 2.5 2.5 2.7 2.8 2.8 2.8 2.9 2.9 3.0 3.2 3.3

3.8 3.94.3 4.5 4.7 4.8

6.3

8.7

11.8

16.0 16.0 16.0

0

2

4

6

8

10

12

14

16

18

20

Y AE X Z U V FF G O R Q CK W F E P A I M K L T S H AA U2 C D J

Material

Bur

n Le

ngth

(cm

)

FAA Requirement: Length < 5.08 cm


0.0 0.3 1.0 1.02.2 2.9

3.8 4.0 4.5 4.55.5 6.0

7.5 8.49.5 10.0

11.513.3 13.9 14.7

15.6

21.0

23.9

29.5

40.0 40.0 40.0 40.0 40.0

0

10

20

30

40

50

60

F R FF H O AE P A E S L M W Q Y AA I G CK V U K T Z C D J N U2

Material

Afte

r Fla

me

Tim

e (s

ec)

FAA Requirement: Time < 3 sec

RADIANT PANEL TEST RESULTSAircraft Ducting Materials

0

5

10

15

20

25

30

35

40

45

0 2 4 6 8 10 12 14 16 18

Burn Length (cm)

Afte

r Fla

me

Tim

e (s

ec)

FAA Requirement: Length < 5.08 cm, AF t < 3 seconds

Passed Test - Sample O: Burn Length = 2.7 cm After Flame Time = 2.2 sec

Failed Test - Sample J: Burn Length = +16 cm After Flame Time = +40 sec

Failed test, but improved Sample K: Burn Length = 2.8 cm After Flame Time = 13.9 sec

FIRE PROTECTION COATING ON SAMPLE K

Sample CKSample K

Failed Test, Sample K: Burn Length = 4.3 cm After Flame Time = 21 sec

RADIANT PANEL EXPERIMENTAL TEST:Test Protocol: Same

Sample Size: Same

Heat Source: Same

Heat Source Exposure: 1 minute exposed to radiant heat, 10 seconds pilot flame impingement

Max Flame Propagation: < 5.08 cm

Max Flame Time: < TBD

EXPERIMENTAL RADIANT PANEL TEST RESULTS Aircraft Ducting Materials

0.0

1.82.1 2.1 2.2 2.3 2.3 2.4

2.8 2.8 3.0 3.23.8 3.9

14.1

16.0 16.0

0

2

4

6

8

10

12

14

16

18

20

Q Y F V X U O FF P Z R E T U2 CK D K

Material

Bur

n Le

ngth

(cm

)

FAA Requirement: Length < 5.08 cm


0.0 0.01.0 1.0 1.6

2.94.2

6.6

15.3

21.2

26.0

35.036.8

40.0 40.0 40.0 40.0

0

10

20

30

40

50

60

F R FF X E O P V U U2 Y Z T CK D K Q

Material

Afte

r Fla

me

Tim

e (s

ec)

EXPERIMENTAL RADIANT PANEL TEST RESULTSAircraft Ducting Materials

0

5

10

15

20

25

30

35

40

45

0 2 4 6 8 10 12 14 16 18

Burn Length (cm)

Afte

r Fla

me

Tim

e (s

ec)

Sugg

este

d M

axim

um P

ropa

gatio

n Le

ngth

= 5

.08

cm

Max Time = ?

Sample O: Burn Length = 2.3 cm After Flame Time = 2.9 sec

Regular Radiant Panel Test

Experimental Radiant Panel Test

Sample K: Burn Length = +16 cm After Flame Time = +40 sec

Regular Radiant Panel Test

Experimental Radiant Panel Test

HEAT RELEASE RATE TEST FOR CABIN MATERIALS:

Test Protocol: Chapter 5 of DOT/FAA/CT-89/15 Aircraft Material Fire Test Handbook


Heat Source: Methane Flame & Radiant Heating Coils (35 kW/m2)

Heat Source Exposure: 5 minutes

Max Avg. Heat Release Rate: <65 kW/m2

Max Avg. Total Heat Released (2 min): <65 kW*min/ m2

FAA/OSU HEAT RELEASE TEST RESULTS Aircraft Ducting Materials

18.9 19.8

29.1 30.2 30.5 33.5 34.3 34.639.8 40.6 40.7 42.0 44.2

53.457.6

63.5 66.3 66.6 68.7 70.5 70.5 70.5 72.2

81.0 82.8

115.3

146.9

179.3

0

20

40

60

80

100

120

140

160

180

200

A I FF F R T E Z S W O U P M H L D B G AC J K Q V C Y X N

Material

Peak

Hea

t Rel

ease

Rat

e (k

W/m

2 )

FAA Requirement: HRR < 65 kW/m2

FAA/OSU HEAT RELEASE TEST RESULTS Aircraft Ducting Materials

8.915.7 18.6

24.4 25.7 25.9 27.6 27.6 29.632.8 34.6 35.7

39.8 40.4 40.5 43.648.0 48.5

57.965.4 66.6

72.9 72.9 72.9

111.8 114.2120.4

132.7

0

20

40

60

80

100

120

140

160

180

200

R A I T O F FF E D G U B P W H Z V S L Q M AC J K C N Y X

Material

Tota

l Hea

t Rel

ease

Rat

e (k

W*m

in/m

2 )

FAA Requirement: THR < 65 kW*min/m2

OSU HEAT RELEASE TESTAircraft Ducting Materials

0

20

40

60

80

100

120

140

0 20 40 60 80 100 120 140 160

OSU Heat Release Peak (kW/m2)

OSU

Tot

al H

eat R

elea

se (k

W*m

in/m

2 )

FAA Requirement 65/65

SMOKE TEST FOR CABIN MATERIALS:

Test Protocol: Chapter 6 of DOT/FAA/CT-89/15 Aircraft Material Fire Test Handbook


Heat Source: Methane Flame & Radiant Heating Coils (25 kW/m2)

Heat Source Exposure: 4 minutes

Max Avg. Specific Optical Density, Dm: <200

FAA/NBS SMOKE TEST RESULTSAircraft Ducting Materials

0 0 0 1 1 1 2 2 4 5 59

12 1218 18 20 22 23 25

41 43

131

176

189 189 189 190

0

20

40

60

80

100

120

140

160

180

200

R A L M P O I W S D E T V G U Z FF X F Q H Y C N AC J K B

Material

Smok

e D

ensi

ty (D

s)

FAA Acceptance Criteria Ds < 200

MICRO-SCALE COMBUSTION CALORIMETER TEST:

Test Protocol: FAA Report DOT/FAA/AR-01/117 A Micro-scale Combustion Calorimeter

Sample Size: milligram range

Heat Source: Heating Coils (900 ºC)

Heat Source Exposure: 10 to 120 seconds to effect pyrolysis

Not a compliance test

MICRO-SCALE COMBUSTION CALORIMETER TEST RESULTSAircraft Ducting Materials

239

322 322 322343 352 358 359 366 366

441 449465 473

486 495 502

546 551 554 561 562 562 563 564 575 578 581594

615 615632

714

0

100

200

300

400

500

600

700

800

C J AC K H AE N Y B X G Q E U2 D S AF FF L M F I W AG A AH U T V P O R Z

Material

Igni

tion

Tem

pera

ture

(deg

C)


921 23 27 31 37 40 41 47

62 64 65 7693 101

112138 148 150 151 153

164 165 167192 195 201

323

355

436

466 473

599

0

100

200

300

400

500

600

700

E D G F Z U2 FF U T I B O H A AF S AG V R AC J K W AH P M L AE Q C Y X N

Material

Peak

Hea

t Rel

ease

Rat

e (W

/g)


2 23 3 3 4 4

55

6 77 7

89 9 9 9 10 10 10 11 11

11 11

14 14 14

2526

27

3132

0

5

10

15

20

25

30

35

E G I T D O A H Z F B FF R P AG AH Q U2 W U S V AF L M J AC K C Y X AE N

Material

Tota

l Hea

t Rel

ease

d (k

J/g)

Therefore, a good fire worthy material is one that has a:

• High Ignition Temperature (at least higher than the expected fire threat)

• Low Total Heat Release

• Low Heat Release Rate

• Low Smoke Emission

• Low Propagation Capacity

Material Fireworthiness Ranking:

Best

Worst

* Ranking based on FAA’s OSU heat release, NBS smoke, and Radiant Panel propagation tests.

12 VBB Material Final Rank

R 1U 2X 3Y 3H 4P 4O 5N 6T 6K 7Q 8

B/AB 9F 10G 11M 12W 13C 14V 15

MATERIAL FINAL RANK

R 1O 2P 3W 4F 5T 6M 7U 8G 9V 10H 11Q 12Y 13X 14B 15C 16K 17N 18

*






INTERMEDIATE-SCALE TEST VS RADIANT PANEL TEST

Urethane Foam Block (Igniter) Heat Flux Profile During Intermediate-Scale Test

0

10

20

30

40

50

60

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Time (Min)

Hea

t Flu

x (k

W/m

2)

Radiant Panel Heat Flux: 17 kW/m2 (1.5 BTU/sec-ft2)

Urethane Foam Block Heat Flux Peak: 49.50 kW/m2

35 secs.

Radiant Heat17 kW/m2

Material will Burn: Ti < 371 degC

Material may Self-Extinguish: Ti > 371 degC

EX RP FINAL RANK

F 1O 2R 2V 2X 2Y 3P 4Q 4U 5T 6C 7K 7N 7

IST Material Final RankF 1W 2Q 3X 3M 4H 5T 5V 5P 6N 7R 7Y 8

AD* 9O 10G 11U 11

B/AB 12K 13C 14

RP FINAL RANK

F 1R 1O 2P 2Y 2Q 3W 3G 4H 4M 4U 4V 4X 5

B/AA/AB 6K 7T 7C 8N 8

RANKING COMPARISON

RADIANT PANEL TEST RESULTSAircraft Ducting Materials

0

5

10

15

20

25

30

35

40

45

0 2 4 6 8 10 12 14 16 18

Burn Length (cm)

Afte

r Fla

me

Tim

e (s

ec)

FAA Requirement: Length < 5.08 cm, AF t < 3 seconds

Material burned significantly during IST test

C, D, N

B, AA, AB

T

EXPERIMENTAL RADIANT PANEL TEST RESULTSAircraft Ducting Materials

0

5

10

15

20

25

30

35

40

45

0 2 4 6 8 10 12 14 16 18

Burn Length (cm)

Afte

r Fla

me

Tim

e (s

ec)

Sug

gest

ed M

axim

um P

ropa

gatio

n Le

ngth

= 5

.08

cm

Max Time = ?

Material burned significantly during IST test

B, C, D, K, NCK

T

Sample D

Sample O

Radiant Panel Test Intermediate-Scale Test (Fire Outside)

Sample D (Failed)

Sample O (Passed)

Exp Radiant Panel Test Intermediate-Scale Test (Fire Inside)

Sample T (Failed)

Sample T (Failed)

Radiant Panel Test

Intermediate-Scale Test (Fire Outside)

Exp Radiant Panel Test

Intermediate-Scale Test (Fire Inside)

What’s Next?:

• Test ducting union and other duct component materials (tapes, silicones, bellows)

• Test fire retardant coatings

• Test new Kaowool board

• Complete testing by 2Q 2006

• Initiate AMOC Draft (By 4Q 2006)

Documents

INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST WORKING … · 11.5 13.3 13.9 14.7 15.6 21.0 23.9 29.5 40.0 40.0 40.0 40.0 40.0 0 10 20 30 40 50 60 F R FF H O AE P A E S L M W Q Y AA I