1. Presented to: By: Date: Federal Aviation Administration International Aircraft Materials Fire Test Working Group Meeting Task Group Session on New Flammability Test for Magnesium-Alloy Seat Structure International Aircraft Materials Fire Test Working Group, Atlantic City Tim Marker, FAA Technical Center October 19-20, 2011

2. 2 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 2 Objective: reproduce results obtained in full-scale tests WE-43: After several minutes of exposure, remove burner, sample burns for approx 1 minute Proposed Magnesium Alloy Flammability Test

3. 3 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 3 Truncated Cone Test Sample of Magnesium Alloy 2” 10”

4. 4 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 4 Planned Activities for Summer 2011 Continue testing of various magnesium alloys, how do they react compared to WE-43 and AZ-31 AZ91E AZ80 ZK60 ZE41 Elektron 21 Elektron 675 …from previous meeting in Bremen

5. 5 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 5 4/11/2011 Problems Encountered with Truncated Cone Repeatability Molten section of cone falls down into pan, no ignition Molten alloy creates thin shape which is ignited; ignition stops after short period Molten alloy creates shape that ignites; ignition of remaining cone occurs, resulting in extended ignition

6. 6 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 6 4/11/2011 Problems Encountered with Truncated Cone Wide range of test results based on melting process

7. 7 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 7 4/11/2011

8. 8 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 8 4/11/2011 Truncated Cone on Side Determine if ignition will continue horizontally 9/20/11 No ignition 6:00 WE-43

9. 9 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 9 4/11/2011 Horizontal Thin Cylinder Sample 9/21/11 Ignition 6:15 Burner off 7:00 AZ-31

10. 10 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 10 4/11/2011 Horizontal Thin Cylinder Sample (post test) 9/21/11 Sample completely burns up

11. 11 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 11 4/11/2011 Horizontally Mounted Thin Rectangular Box 9/22/11 Determine ignition/burning on thin-walled specimen

12. 12 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 12 4/11/2011 Horizontally Mounted Thin Rectangular Box 9/22/11

13. 13 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 13 4/11/2011 Horizontally Mounted Thin Rectangular Box 9/22/11 Burner off 5:00 Burn at 4:10 Sample out 6:20 After burn 1:20

14. 14 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 14 4/11/2011 Horizontally Mounted Thin Rectangular Baggage Bar 9/22/11

15. 15 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 15 4/11/2011 Horizontally Mounted Thin Rectangular Baggage Bar 9/22/11

16. 16 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 16 4/11/2011 Horizontally Mounted Thin Rectangular Baggage Bar 9/22/11 Burner off 4:00 Burn at 2:50 Sample out 4:20 After burn 0:20

17. 17 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 17 4/11/2011 Leg Plate “I” Web Mounted Horizontally 9/22/11

18. 18 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 18 4/11/2011 Leg Plate “I” Web Mounted Horizontally 9/22/11

19. 19 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 19 4/11/2011 Leg Plate “I” Web Mounted Horizontally 9/22/11 Burner off 5:00 Burn at 4:45 Sample out 6:30 After burn 1:30

20. 20 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 20 4/11/2011 9/27/11 3/16” Vertical Web x ½” Horizontal Web “T” Web Machined from Leg Post, Mounted Horizontally

21. 21 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 21 4/11/2011 9/27/11 “T” Web Machined from Leg Post, Mounted Horizontally 3/16” Vertical Web x ½” Horizontal Web

22. 22 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 22 4/11/2011 9/28/11 “T” Web Machined from Leg Post, Mounted Horizontally 1/8” Vertical Web x ½” Horizontal Web Burner off 5:00 Burn at 4:35 Sample out 5:00 After burn 0:00

23. 23 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 23 4/11/2011 9/28/11 “T” Web Machined from Leg Post, Mounted Horizontally 1/16” Vertical Web x ½” Horizontal Web

24. 24 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 24 4/11/2011 9/28/11 “T” Web Machined from Leg Post, Mounted Horizontally 1/16” Vertical Web x ½” Horizontal Web Burner off 5:00 Burn at 4:50 Sample out 5:50 After burn 0:50

25. 25 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 25 4/11/2011 Inverted Cone WE-43, Suspended Vertically 9/29/11

26. 26 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 26 4/11/2011 Inverted Cone WE-43, Suspended Vertically 9/29/11

27. 27 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 27 4/11/2011 Inverted Cone WE-43, Suspended Vertically 9/29/11 Burner off 5:00 Sample out 5:00 After burn 0:00

28. 28 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 28 4/11/2011 Inverted Thinner Cone AZ-31, Suspended Vertically 9/29/11

29. 29 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 29 4/11/2011 Inverted Thinner Cone AZ-31, Suspended Vertically 9/29/11

30. 30 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 30 4/11/2011 Inverted Thinner Cone AZ-31, Suspended Vertically 9/29/11

31. 31 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 31 4/11/2011 Inverted Thinner Cone AZ-31, Suspended Vertically 9/29/11 Burner off 4:00 Sample out 4:00 After burn 0:00 Burn at 0:35

32. 32 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 32 4/11/2011 9/29/11 Inverted Thinner Cone AZ-31, Suspended Vertically (repeat) Burner off 4:00 Sample out 4:00 After burn 0:00 Burn at 0:35

33. 33 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 33 4/11/2011 9/30/11 Test 1 Circular Tube WE-43, Mounted Horizontally

34. 34 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 34 4/11/2011 9/30/11 Test 1 Circular Tube WE-43, Mounted Horizontally Burner off 4:00 Sample out 5:40 After burn 1:40 Burn at 2:50

35. 35 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 35 4/11/2011 9/30/11 Test 2 Circular Tube WE-43, Mounted Horizontally

36. 36 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 36 4/11/2011 Circular Tube WE-43, Mounted Horizontally Test 2 9/30/11 Burner off 4:00 Sample out 5:30 After burn 1:30 Burn at 2:27

37. 37 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 37 4/11/2011 Circular Tube WE-43, Mounted Vertically 9/30/11 Test 1

38. 38 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 38 4/11/2011 Test 1 Circular Tube WE-43, Mounted Vertically 9/30/11

39. 39 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 39 4/11/2011 Circular Tube WE-43, Mounted Vertically Test 1 9/30/11 Burner off 4:00 Sample out 5:20 After burn 1:20 Burn at 2:28

40. 40 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 40 4/11/2011 Test 2 Circular Tube WE-43, Mounted Vertically 9/30/11 Burner off 4:00 Sample out 5:35 After burn 1:35 Burn at 2:33

41. 41 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 41 4/11/2011 9/30/11 Various Tested Samples

42. 42 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 42 4/11/2011 10/03/11 Circular Tube WE-43, Test Results

43. 43 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 43 4/11/2011

44. 44 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 44 4/11/2011 Circular Tube Aluminum, Mounted Vertically Test 1 10/03/11 …for comparison to mag-alloy samples

45. 45 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 45 4/11/2011 …for comparison to mag-alloy samples Circular Tube Aluminum, Mounted Vertically 10/03/11

46. 46 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 46 4/11/2011 …for comparison to mag-alloy samples Circular Tube Aluminum, Mounted Vertically 10/03/11

47. 47 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 47 4/11/2011 Standard 8-inch WE-43 cone drilled-out, 5.5 inches high Conical Tube WE-43, Mounted Vertically 10/04/11

48. 48 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 48 4/11/2011 Conical Tube WE-43, Mounted Vertically 10/04/11 Standard 8-inch WE-43 cone drilled-out, 5.5 inches high, volcano effect Burner off 5:00 Sample out 23:00 After burn 18:00 Burn at 4:30

49. 49 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 49 4/11/2011 Conical Tube WE-43, Mounted Vertically 10/05/11 Standard 8-inch WE-43 cone drilled-out, 5.5 inches high (repeat)

50. 50 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 50 4/11/2011 Conical Tube WE-43, Mounted Vertically 10/05/11 Standard 8-inch WE-43 cone drilled-out, 5.5 inches high (repeat) Burner off 6:00 Sample out 6:00 After burn 0:00 Burn: none

51. 51 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 51 4/11/2011 10/06/11 Rectangular Box Section WE-43, Mounted Vertically

52. 52 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 52 4/11/2011 10/06/11 Rectangular Box Section WE-43, Mounted Vertically Burner off 5:00 Sample out 5:00 After burn 0:00 Ign at 3:20

53. 53 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 53 4/11/2011 10/06/11 Rectangular Box Section WE-43, Mounted Vertically (rotate 90 o )

54. 54 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 54 4/11/2011 10/06/11 Rectangular Box Section WE-43, Mounted Vertically (rotate 90 o ) Burner off 5:00 Sample out 8:30 After burn 3:30 Burn at 2:40

55. 55 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 55 4/11/2011 10/11/11 milled-out WE-43 cone, 5.5 inches high (3 inch deep milling) 10/11/11 Conical Tube WE-43, Mounted Vertically

56. 56 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 56 4/11/2011 10/11/11 milled-out WE-43 cone, 5.5 inches high (3 inch deep milling) Burner off 5:00 Sample out 5:00 After burn 0:00 Burn at 4:48 Conical Tube WE-43, Mounted Vertically

57. 57 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 57 4/11/2011 Summary of Results Truncated cone sample suffered from repeatability issues: Duration of burning following burner flame removal also dependent on resulting molten shape Time of ignition dependent on resulting molten shape Hollow cylinder test sample demonstrates good repeatability Time of ignition and duration of after flame very consistent Resulting molten shape also very repeatable, demonstrating test robustness Hollow cross-sections demonstrated better ignitability than solid cross-sections Thinner wall has tendency to ignite simultaneous to melting Thick cross sections melt into complex shapes prior to ignition, reducing repeatability

58. 58 of 58 Federal Aviation Administration Task Group Session on Seat Structure Test October 19, 2011 58 Planned Activities Continue with testing of hollow cylinders to further define repeatability Experiment with smaller diameter hollow cylinders to determine repeatability Experiment with hollow cylinders in other mag-alloys? Begin to refine test parameters (i.e., time to ignition, exposure time, after flame duration) Experiment with other hollow shapes?