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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
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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?
