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Surrogate Testingand
Proposed Certification Procedures for Altered Interior Surfaces
Tim Marker
FAA Technical Center
-the difficulties associated with the fire test approval of renovatedmaterial systems,
-investigates the results of heat release and flammability tests conducted usingsurrogate materials produced by three independent manufacturers.
This report discusses:
“Heat Release and Flammability Testing of Surrogate Panels”
Problem: How to administer OSU or VBB certification tests on renovated cabin interiorsurfaces when appropriate test substrates are unavailable.
Objective: To determine if surrogate materials can be used as accurate HR and BLpredictors for in-service materials being renovated.
A substrate used in-place of existing interior panels for the purposes of conductingHR or VBB certification tests.
A substrate which has the same basic construction and build-up as the OEM Panel,with a comparable lay-up process during manufacture.
Honeycomb core thickness, number of pre-preg plies per side, and reinforcement mustbe identical to the in-service panel.
Surrogate Material:
Surrogate Test Panel Basic Construction
Paint/Decorative Laminate
Top-Facing 2-ply Fiberglass
Bottom-Facing 2-ply Fiberglass
Core: 0.50-inch Nomex Paper/Phenolic Resin
Test type Panel fabricator Finish type Finish fabricator Renovation Number of TestsH = Heat Release B (Boeing) P = Paint Q HSH Aerospace X = No Renovation (in parenthesis)
F = Flammability C (C&D Interiors) L = Dec Laminate R Boeing Y = PaintD (Skyline Prod) S Mankiewicz Z = Dec Laminate
T SchnellerU Boeing
Panel Description Code
Finish Q Finish R Finish S Finish T Finish UPanel B HBPQX (15) HBPRX (15) HBPSX (13) HBLTX (15) HBLUX (15)Panel C HCPQX (15) HCPRX (15) HCPSX (12) HCLTX (15) HCLUX (15)Panel D HDPQX (16) HDPRX (16) HDPSX (16) HDLTX (16) HDLUX (16)
Heat Release Test Matrix
Finish Q Finish R Finish S Finish T Finish UPanel B FBPQX (15) FBPRX (15) FBPSX (15) FBLTX (15) FBLUX (15)Panel C FCPQX (15) FCPRX (15) FCPSX (15) FCLTX (15) FCLUX (15)Panel D FDPQX (15) FDPRX (15) FDPSX (15) FDLTX (16) FDLUX (16)
Flammability Test Matrix
Panel Type Total HR (kW/m2)min Peak HRR (kW/m2)Panel B Baseline1 30.48 33.63Panel B Baseline2 29.89 32.52Panel B Baseline3 27.45 32.07
Average 29.27 32.74
Panel Type Total HR (kW/m2)min Peak HRR (kW/m2)Panel C Baseline1 35.23 31.27Panel C Baseline2 26.70 25.43Panel C Baseline3 32.13 28.39
Average 31.35 28.36
Panel Type Total HR (kW/m2)min Peak HRR (kW/m2)Panel D Baseline1 32.78 35.85Panel D Baseline2 26.07 28.98Panel D Baseline3 20.25 30.06
Average 26.37 31.63
Surrogate Testing
Baseline Panel Numerical Averages
Panel B Baseline
-5
0
5
10
15
20
25
30
35
40
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se (
kW/m
2)
Run 1
Run 2
Run 3
Surrogate Testing
Panel C Baseline
-5
0
5
10
15
20
25
30
35
40
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se (
kW/m
2)
Run 1
Run 2
Run 3
Surrogate Testing
Panel D Baseline
-5
0
5
10
15
20
25
30
35
40
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se (
kW/m
2 )
Run 1
Run 2
Run 3
Surrogate Testing
Point-by-Point Average
-5
0
5
10
15
20
25
30
35
40
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se (
kW/m
2 )
B AVE
C AVE
D AVE
Baseline Comparison
Heat Release Average (Point-by-Point)
-5
5
15
25
35
45
55
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se R
ate
(kW
/m2 )
HBPQX AVE (15 TESTS)HCPQX AVE (15 TESTS)HDPQX AVE (12 TESTS)
Paint Q Comparison
Heat Release Average (Point-by-Point)
-5
5
15
25
35
45
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se R
ate
(kW
/m2 )
HBPRX AVE (15 TESTS)
HCPRX AVE (15 TESTS)
HDPRX AVE (12 TESTS)
Paint R Comparison
Heat Release Average (Point-by-Point)
-5
5
15
25
35
45
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se R
ate
(kW
/m2 )
HBPSX AVE (13 TESTS)
HCPSX AVE (12 TESTS)
HDPSX AVE (11 TESTS)
Paint S Comparison
Heat Release Average (Point-by-Point)
-5
0
5
10
15
20
25
30
35
40
45
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se R
ate
(kW
/m2 )
HBLTX AVE (15 TESTS)
HCLTX AVE (15 TESTS)
HDLTX AVE (15 TESTS)
Laminate T Comparison
Heat Release Average (Point-by-Point)
-5
0
5
10
15
20
25
30
35
40
45
0 30 60 90 120 150 180 210 240 270 300
Time (seconds)
Hea
t R
elea
se R
ate
(kW
/m2 )
HBLUX AVE (15 TESTS)
HCLUX AVE (15 TESTS)
HDLUX AVE (12 TESTS)
Laminate U Comparison
Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR
Panel B Average 29.27 32.74 37.23 35.55 7.95 2.81
Panel C Average 31.35 28.36 40.30 46.79 8.95 18.43
Panel D Average 26.37 31.63 39.90 46.61 13.54 14.98
Unfinished Finish Q Increase
Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR
Panel B Average 29.27 32.74 43.90 35.93 14.63 3.19
Panel C Average 31.35 28.36 40.05 35.40 8.69 7.03
Panel D Average 26.37 31.63 44.91 43.22 18.54 11.59
Unfinished Finish R Increase
Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR
Panel B Average 29.27 32.74 40.08 35.48 10.80 2.74
Panel C Average 31.35 28.36 32.89 35.31 1.54 6.94
Panel D Average 26.37 31.63 36.13 36.43 9.77 4.80
Unfinished Finish S Increase
Surrogate Testing Results
Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR
Panel B Average 29.27 32.74 40.01 36.31 10.74 3.57
Panel C Average 31.35 28.36 50.59 39.41 19.23 11.05
Panel D Average 26.37 31.63 41.30 39.29 14.93 7.66
Unfinished Finish T Increase
Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR
Panel B Average 29.27 32.74 39.79 42.41 10.51 9.67
Panel C Average 31.35 28.36 47.82 36.24 16.46 7.88
Panel D Average 26.37 31.63 41.58 39.49 15.21 7.86
Unfinished Finish U Increase
Surrogate Testing Results
Conclusions
Normal fluctuations between different labs will only compound the inaccuracy of test results.
Unfinished surrogate panels did not produce nearly-identical HRR traces, but differentpeaks that occurred at different times.
HRR differences are compounded when various finishes are applied; these cases representtypical in-service situations likely to occur during certification testing of renovated interiors.
All tests were performed:
At one facility,
With one tester,
Based on a large number of replicate tests;
Conclusions (con’t)
Based on the above, it would be very difficult to adopt a standardized procedurein which renovated interiors could be certified using surrogate materials.
Expectation: The increase in HR caused by a particular paint or decorative should beindependent of the identity of the surrogate panel.
Result: HR increase not independent of surrogate identity
Proposed Methodology for Certifying Renovations/Alterations(65/65 interior)
Option 1: Use flat panel spares supplied by manufacturer of A/C
Option 2: Use Cut-out specimen from A/C TBM (To Be Modified)
Option 3: If the original HR information is available for the component TBM, and the HRR is:
Less than 35/35: Fabricate and use surrogate specimen with HRR NLT 40/40
Less than 45/45, but greater than 35/35: Fabricate and use surrogate specimen with HRR NLT 50/50
Less than 55/55, but greater than 45/45: Fabricate and use surrogate specimen with HRR NLT 60/60
Greater than 55/55: Fabricate and use surrogate specimen with HRR NLT 63/63
*note: surrogate specimen must mimic the interior component TBM in every way, including core type,resin type, and thickness and number of pre-preg plies, plus any/all finishes such as paint or decorative.
*note: if original HR information is not available, this approach cannot be utilized.
Proposed Methodology for Certifying Renovations/Alterations(Pre 65/65 interior)
Option 1: Use flat panel spares supplied by manufacturer of A/C
Option 2: Use Cut-out specimen from A/C TBM (To Be Modified)
Option 3: If the original 60sec VBB information is available for the component TBM, and the BL is:
*note: surrogate specimen must mimic the interior component TBM in every way, including core type,resin type, and thickness and number of pre-preg plies, plus any/all finishes such as paint or decorative.
*note: if original 60sec VBB information is not available, then a surrogate specimen with BL NLT 5.5 inches may be used
Less than 1 inch: Fabricate and use surrogate specimen with BL NLT 1.5 inches
Less than 2 inches, but greater than 1 inch: Fabricate and use surrogate specimen with BL NLT 2.5 inches
Less than 3 inches, but greater than 2 inches: Fabricate and use surrogate specimen with BL NLT 3.5 inches
Less than 4 inches, but greater than 3 inches: Fabricate and use surrogate specimen with BL NLT 4.5 inches
Less than 6 inches, but greater than 4 inches: Fabricate and use surrogate specimen with BL NLT 5.5 inches
