Federal Aviation International Aircraft Materials Fire Test Working … · 2015. 10. 27. ·...

Presented to:

By:

Date:

Federal Aviation Administration

International Aircraft

Materials Fire Test

Working Group Meeting

Development of a New Flammability Test for

Magnesium-Alloy Seat Structure

International Aircraft Materials Fire Test

Working Group, Atlantic City, NJ

Tim Marker, FAA Technical Center

October 19-20, 2015

2 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Round Robin III: Results obtained so far

Small-scale flammability test results using Radiant Panel

Discussion Items for Task Group/Future

Magnesium Alloy Flammability Highlights

Mag Use in Other Areas: What is the appropriate method of testing?

Development of Acceptance Criteria for Allowing Use of Oil Burner

3 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Purpose: To help identify differences in labs. Results will help in the

development of a repeatable test.

Technique: Test identically-prepared samples under controlled conditions

Participants: FAA, Accufleet, Airbus, Magnesium Elektron

Equipment: Igniterless stator, spark plug, new clamp-style

sample holder, 20 samples of EL43, 1 sample AZ31

Magnesium Alloy Flammability Test Round Robin III

4 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

1000

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Burner Flame Temperature Check

Pre-Test Temperature Check

Post-Test Temperature Check

Lab A Lab C Lab E Lab F

5 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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Bar Begins to Burn (Seconds)

Bar Out (Seconds)

Weight Loss (%)

Lab A Lab C Lab E Lab F

6 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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Round Robin III Using EL43 Samples

Melt (Seconds)

Lab A Lab C Lab E Lab F

7 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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Round Robin III Using EL43 Samples

Bar Begins to Burn (Seconds)

Lab A Lab C Lab E Lab F

8 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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Round Robin III Using EL43 Samples

Bar Out (Seconds)

Lab A Lab C Lab E Lab F

9 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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Round Robin III Using EL43 Samples

Weight Loss (%)

Lab A Lab C Lab E Lab F

10 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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10.0Average Weight Loss of 20 Samples

Average Weight Loss, Including Zeros

Average Weight Loss, Excluding Zeros

Lab A Lab C Lab E Lab F

11 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Magnesium Alloy Flammability Test Round Robin III

Preliminary Findings:

Melt times consistent between labs, indicating samples being exposed similarly

Time when sample begins to burn also consistent between labs

Time for sample to self extinguish remains inconsistent

Weight Loss results still an issue, with excessive scatter

Temperature Check shows burner flame agreement using igniterless stator

Further analysis to follow now that all data received

12 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

The Use of Magnesium Alloy in Other Cabin Areas

Use in 5 primary

seat components

Use in other

cabin components

accessible inaccessible

Use in other non-

primary seat

components

What is the appropriate method of test?

Oil Burner Oil Burner ?

Oil Burner ? Elec Arc ?

13 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Surface Area-to-Volume (SAV) Ratios of Seat Components

Low SAV ratio = low probability of ignition

High SAV ratio = high probability of ignition

Part Description Surface Area (in2) Volume (in3) SAV ratio

Test sample 70.750 7.500 9.43

Leg assembly 193.474 24.661 7.85

Front leg 77.315 7.583 10.20

Center spreader 237.049 18.225 13.01

Wall spreader 175.869 13.446 13.08

Aisle spreader 291.297 19.266 15.12

Backrest Frame 581.000 36.250 16.03

Crosstube 579.616 34.704 16.70

Baggage Bar 373.357 10.073 37.07

14 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

…from previous IAMFTWG meeting…

• SAV ratio of flat panels ~ 2/t

• SAV ratio of hollow tubes ~ 2/t

• For a SAV < test sample, a flat panel or hollow tube would have to be:

…at least 0.2 inches thick

Parts tested during full-scale tests (cross tubes, seat back, baggage bar) were

substantially less thick (0.06 inches, 0.125 inches, 0.054 inches)

However…

So…

Propose 2 different SAV ratios: max 20 for solid parts, max 40 for hollow parts

The Use of Surface Area-to-Volume (SAV) to Predict Flammability

15 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Surface Area-to-Volume (SAV) Ratios of Seat Components

Part Description Surface Area (in2) Volume (in3) SAV ratio

Test sample 70.750 7.500 9.43

Leg assembly 193.474 24.661 7.85

Front leg 77.315 7.583 10.20

Center spreader 237.049 18.225 13.01

Wall spreader 175.869 13.446 13.08

Aisle spreader 291.297 19.266 15.12

Backrest Frame 581.000 36.250 16.03

Crosstube 579.616 34.704 16.70

Baggage Bar 373.357 10.073 37.07

SAV ratio solid ≤ 20

SAV ratio hollow ≤ 40

16 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

The Use of Magnesium Alloy in Other Cabin Areas

Use in 5 primary

seat components

Use in other

cabin components

accessible inaccessible

Use in other non-

primary seat

components

What is the appropriate method of test?

Oil Burner Oil Burner

Oil Burner ? Elec Arc ?

?

17 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Possible Criteria for Allowing Substantiation of non-Seat

Components Using the Oil Burner per Chapter 25

2. Surface Area-to-Volume (SAV) Ratios (≤ 20 solids, ≤ 40 hollow)

1. Component is accessible

3. Component is Located at Height Comparable to Seat Height

4. Proximity to Electrical Components is Minimized

18 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

The Use of Magnesium Alloy in Other Cabin Areas

Use in 5 primary

seat components

Use in other

cabin components

accessible inaccessible

Use in other non-

primary seat

components

What is the appropriate method of test?

Oil Burner

Elec Arc ? ? Oil Burner

Oil Burner

19 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Small Scale Testing

20 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Electrical Arc Testing of Thin Magnesium Alloy Samples

electrode

Thin sample

21 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

EL43

0.100-inch thickness

Testing of Thin Magnesium Samples in VBB

22 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

EL43

0.050-inch thickness

Testing of Thin Magnesium Samples in VBB

23 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Testing of Thin Magnesium Samples in VBB

0.125-inch thickness

AZ31

24 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Testing of Thin Magnesium Samples in Radiant Panel

25 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Testing of Thin Magnesium Samples in Radiant Panel

26 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Testing of Thin Magnesium Samples in Radiant Panel

27 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Testing of Thin Magnesium Samples in Radiant Panel

28 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Testing of Thin Magnesium Samples in Radiant Panel

29 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

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EL43 Time of Ignition

AZ31 Time of Ignition

0.025 inch 0.055 inch 0.125 inch

no ignition no ignition

30 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Discussion Items for Task Group

Continue the development of substantiation criteria for allowing the use of the

oil burner for non-primary seat components (ex: tray table arms)

Continue radiant panel testing of thin magnesium alloy samples, develop

pass/fail criteria for inaccessible area components

Continue the development of substantiation criteria for allowing the use of the

oil burner for non-seat components (ex: galley carts)

31 of 31 Federal Aviation Administration

Development of a Flammability Test for Magnesium Alloys

October 19, 2015

Questions?