Presented to: International Aircraft Materials Fire Test Working Group, Atlantic City By: Rich Lyon, AJP-6320 Date: October 21, 2009 Federal Aviation Administration QUALIFICATION TEST FOR A/C PANEL ADHESIVES

International Materials Fire Test Working Group October 21, Federal Aviation Administration Establish similarity of bonded details. OBJECTIVEOBJECTIVE PURPOSEPURPOSE Develop a qualification test for flammability of adhesives used in bonded details. APPLICATIONSAPPLICATIONS Certification of New Parts

International Materials Fire Test Working Group October 21, Federal Aviation Administration ADHESIVES TASK GROUP 3M American Airlines Boeing Bombardier Bostik C&D Aerospace Dassault FAA Henkel

International Materials Fire Test Working Group October 21, Federal Aviation Administration INDUSTRY-PROPOSED METHODS OF COMPLIANCE FOR CERTIFICATION OF INTERIOR MATERIALS BONDED DETAILS (a) Bunsen Burner Similarity Bunsen Burner Similarity25.853(d) Heat and Smoke Similarity Testing detail without adhesive* to Appendix F substantiates the bonded configuration Test required if: A > 2 ft 2 Possible Test if: 1 < A < 2 ft 2 No test required* if: A < 1 ft 2 Ref. No. Feature / Construction Part 2: Methods That Will Require Supporting Data *For FAA Qualified Adhesives?

International Materials Fire Test Working Group October 21, Federal Aviation Administration ADHESIVE QUALIFICATION TEST ISSUES FAR 25 versus Other Measurement Method Sample Form Effect of Adherends Effect of Thickness: Does thinner substantiate thicker?

International Materials Fire Test Working Group October 21, Federal Aviation Administration Thickness, inches Peak Heat Release Rate, kW/m 2 Total Heat Release, kW-min/m 2 Peak HRR Total Heat Release Example: Thermoplastic Thickness Ranges OSU Peak HRR of  does not substantiate.080   EUROPLEX PPSU Clear Proposed range

International Materials Fire Test Working Group October 21, Federal Aviation Administration Combustor Mixing Section Pyrolyzer Sample Cup Scrubber Flow Meter O 2 Sensor Exhaust Purge Gas Inlet Sample Post & Thermocouple Oxygen Inlet Standard Test Method for Measuring Flammability Properties of Plastics and Other Solid Materials Using Microscale Combustion Calorimetry, ASTM D 7309

International Materials Fire Test Working Group October 21, Federal Aviation Administration Heat Release Rate (J/g-K) Temperature (°C) cc hchc TpTp  Noncombustible Fraction (g/g) THERMAL COMBUSTION PROPERTIES FROM MCC Peak Heat Release Rate = Heat Release Capacity (J/g-K) Total Heat Release (J/g)  Burning Temperature

International Materials Fire Test Working Group October 21, Federal Aviation Administration PP PE PS PET ABS PMMA Epoxy POM NYLON 66 PC PPO PU PAR PPSU PPS PES PEI LCP PAI PEK PEEK Materials Cost* ($/lb) Phenolic KAPTON PVF Heat Resistant Plastics PSU PVC (rigid) Commodity Plastics *Truckload Prices, 2001 Engineering Plastics Heat Release Capacity (  c ), J/g-K TYPICALLY PASS FAA HRR TEST HEAT RELEASE CAPACITY VERSUS COST OF PLASTICS

International Materials Fire Test Working Group October 21, Federal Aviation Administration Probability of Passing VBB, p Heat Release Capacity  c, J/g-K  *= 448 J/g-K n = 4.46 R = 0.97  *= 448 J/g-K n = 4.46 R = 0.97 ASTM D 3801 VERTICAL BUNSEN BURNER TEST (114 plastics) Probability of Passing the UL 94 V-0 Requirement

International Materials Fire Test Working Group October 21, Federal Aviation Administration HAND LAY-UP OF ADHESIVE / RESIN OSU SAMPLES Fiberglass-reinforced adhesive samples are made by hand lay-up. Samples cured between two Teflon-coated aluminum plates in heated press. Cured samples trimmed to 6  x 6  for OSU HRR testing. Resulting samples ~ 40% resin by weight.

International Materials Fire Test Working Group October 21, Federal Aviation Administration OSU TESTING OF ADHESIVE RESINS 2-min HR (kW-min/m 2 ) Peak HRR (kW/m 2 ) Resin 44111BPA Epoxy 2688BPAE + MDA 2872BPA CE 2848BPC Epoxy 1233Silicone Resin 13 BPC CE

International Materials Fire Test Working Group October 21, Federal Aviation Administration (R = ) avg  pHRR , kW/m 2  c , J/g-K OSU PHRR (binned data) 101 RESINS AND PLASTICS) Maximum Heat Release Capacity from Curve Fit

International Materials Fire Test Working Group October 21, Federal Aviation Administration HRR  65 kW/m 2 = Pass = P HRR > 65 kW/m 2 = Fail = F pHRR /10 = /10 = /10 = /10 = /10 = 0.00 cc p = P/(P + F)  c  Etc. y OSU Data for AIRCRAFT CABIN MATERIALS Transform Quantitative Data into Qualitative Data Using Pass/Fail Criterion 14 CFR PPPPFPPPPFPPFPPFPPFFFPFPFFPPFPFFFFPPFFFFFFFFFPPPPFPPPPFPPFPPFPPFFFPFPFFPPFPFFFFPPFFFFFFFFF

International Materials Fire Test Working Group October 21, Federal Aviation Administration Probability of Passing OSU pHRR, p Heat Release Capacity (  c ), J/g-K  *= 140 J/g-K n = 2.4 R = 0.97  *= 140 J/g-K n = 2.4 R = CFR 25 OSU PHRR (101 RESINS AND PLASTICS) Probability that pHRR  65 kW/m = 102 J/g-K

International Materials Fire Test Working Group October 21, Federal Aviation Administration Adhesive Part Substrate  p,  p  a,  a  s,  s  i = Areal Density of Layer i, g/m 2  i = Heat Release Capacity of Layer in MCC i, J/g-K m i = Mass Fraction of Layer i =  i /  i EFFECT OF ADHERENDS and THICKNESS (Additive Approach Using MCC Data)  construction = m p  p + m a  a + m s  s

International Materials Fire Test Working Group October 21, Federal Aviation Administration Adhesive Part Substrate T i, , h c, E, A, etc. T i = Thickness of Layer i, cm  i = Density of Layer i, g/m 3 h i = Heat Release of Layer, J/g E i, A i = Thermal Decomposition Kinetic Parameters of i EFFECT OF ADHERENDS and THICKNESS (ThermaKin Numerical Burning Model) T i, , h, E, A, etc. Transient energy and mass balance calculation

International Materials Fire Test Working Group October 21, Federal Aviation Administration OSU HRR OF BONDED CONSTRUCTION (ThermaKin Simulation) Heat Flux = 35 kW/m 2 (OSU) + 15 kW/m 2 (Flame) Heat Flux = 35 kW/m 2 (OSU) + 15 kW/m 2 (Flame) Adhesive Layer Thickness = 0.2, 0.5, 1 and 1.5 mm h c = 2X Substrate Substrates = 1/16  (1.5 mm) Thick Charring Plastic (Polycarbonate)

International Materials Fire Test Working Group October 21, Federal Aviation Administration mm Adhesive Layer mm Adhesive Layer mm Adhesive Layer HRR (arbitrary units) HR (arbitrary units) Time, min mm Adhesive Layer Time, min OSU HRRs of BONDED CONSTRUCTIONS (ThermaKin)