1. RANKING FLAMMABILITY OF AIRCRAFT MATERIALS USING MICROSCALE COMBUSTION CALORIMETRY Richard E. Lyon and Richard N. Walters* Fire Safety Branch AAR-440 FAA W.J. Hughes Technical Center Atlantic City International Airport, NJ 08405 *Galaxy Scientific Corporation, Egg Harbor Township, NJ International Aircraft Materials Fire Test Working Group Trump Taj Mahal Casino, Atlantic City, NJ March 1-2, 2005 WEB: www.fire.tc.faa.govE-MAIL: Richard.E.Lyon@faa.govwww.fire.tc.faa.gov

2. RANKING FLAMMABILITY USING SMALL SCALE TEST OUTLINE OF TALK Flammability Ignition Resistance (0 , 90 , 60 ,45  Bunsen burner) Fire Behavior (OSU, seat cushion test, radiant panel) Microscale Combustion Calorimetry Operation and Theory Comparison of Results for Hidden Materials Heat Release Rate (OSU) Bunsen Burner tests Smoke Density Radiant Panel 1/4-scale tests

3. FAA FLAMMABILITY TESTS Seat Cushion Oil Burner Test Radiant Panel Test OSU HRR Test Bunsen Burner Tests

4. SCALES OF FLAMMABILITY TESTING SAMPLE SIZE Flame Tests Fire Tests Bench-ScaleComponent-Scale Microscale Combustion Calorimetry Kilogram Metric TonGramMilligram

5. STEADY BURNING: Nylon 6 data 500 1000 1500 2000 0 20406080100120 PA6 External Heat Flux, kW/m 2 HRP 14 21 Slopes = HRP Intercepts = HRR 0 HRR 0 (kW/m 2 ) 230 148 Heat Release Rate, kW/m 2 Ignitability Fire Response HRR = HRP q  net = HRR 0 + HRP q  ext..

6. -400-2000200400600 V0 V1 V2 HB UL 94 Rating HRR 0, kW/m 2 (in cone calorimeter) Self-PropagatingSelf-Extinguishing IGNITABILITY: UL 94 vs. HRR 0 41 polymers, blends, and composites.

7. HEAT RELEASE RATE AND HEAT RELEAE CAPACITY The Heat Release Capacity (HRC), is related to the heat release rate (HRR) in flaming combustion 0 500 1000 1500 2000 0500100015002000 Peak HRR, kW/m 2 2 Heat Release Capacity, J/g-K R = 0.93 PVC PEI PPS POM PET PVDF PC PMMA ABS PA66 HIPS PP HDPE 50 kW/m 2 FEP HRR = (  ) HRC  HRC  = Flaming combustion efficiency  = Density  = Pyrolysis depth  = Surface heating rate

8. HEAT RELEASE CAPACITY AND FLAMMABILITY HRR 0  HRR* = HRC* HEAT RELEASE RATE IGNITABILITY HRR  HRC* Self extinguishing when: For a particular heat flux (e.g., 3.5 W/cm 2 ):

9. MEASURING HEAT RELEASE CAPACITY Flaming Combustion Pyrolysis-Combustion Flow Calorimetry (PCFC) Exhaust DAQ O2O2 Pyrolysis Combustion Sample Gas Scrubber Gas Flow- meter O 2 Meter N2N2

10. FLAMMABILITY TESTING OF MILLIGRAM SAMPLES Stand Alone Device FAA/Galaxy Invention TGA Combustion Accessory

11. HEAT RELEASE CAPACITY FROM PCFC 260 W/g  = 1 K/s

12. 0 100 200 300 400 500 250300350400450500550 Heat Release Rate (W/g) Temperature (°C) PCFC DATA & FIRE TESTS OSU HRR Bunsen Burner Ignition Radiant Panel Oil Burner Seat Test Oxygen Bomb Calorimeter Setchkins Furnace Glow Wire Ignition Relevant FAA Flammability Test Burning Rate Heat of Combustion Ignition Temperature PMMA Combustion Calorimetry Data

13. IGNITION RESISTANCE (UL 94) AND HRC 10 100 1000 10,000 HB V2 V1 V0 Heat Release Capacity, J/g-K UL 94 Rating Halogen containing Flammability

14. IGNITION RESISTANCE (LOI) AND HRC 0 20 40 60 80 100 101001000 Limiting Oxygen Index (LOI), %O 2 Heat Release Capacity, J/g-K 10,000 Halogen containing

15. 12 SECOND VERTICAL BURN TEST AND HRC 0 2 4 6 8 10 -2 0 2 4 6 8 10 0100200300400500600 Burn Length (cm) Burn Time (seconds) HRC (J/g-K) Hidden Materials

16. 1 10 100 10100100010 4 Engineering Plastics Commodity Plastics Hidden Area Components HEAT RELEASE PARAMETER HRC (J/g-K) FIRE (HRP) AND MATERIAL (HRC) PROPERTIES HRP = HRC  q  net   cpcp Slope should be relatively constant for plastics for well-ventilated burning

17. 0 50 100 150 200 250 300 350 0100200300400500600700 OSU Peak HRR, kW/m 2 Heat Release Capacity, J/g-K R = 0.72 Engineering Thermoplastics (0.060 inch sheet) HRR (OSU PEAK) AND HRC

18. 0.01 0.1 1 10 100 1000 0100200300400500600 Smoke Density, D s HRC (J/g-K) NBS SMOKE DENSITY AND HRC Hidden Materials

19. 0 5 10 15 20 25 0100200300400500600 BURN TIME, seconds HRC (J/g-K) RADIANT PANEL TEST AND HRC Hidden Materials

20. TEMPERATURE RISE AND HRC OF INSULATION BAGS PVF1 (120 J/g-K) PUF block, Baseline MPET (262 J/g-K) PI-O (47 J/g-K) PET1 (138 J/g-K) PET3 (250 J/g-K) PET00 (155 J/g-K) INTERMEDIATE SCALE TEST AND HRC

21. 050100150200250 Metalized Mylar Bag Hook & Loop (married) Cockpit Headliner GRP Duct Plastic Conduit Ceiling Panel (back) Flexside Duct Ceiling Panel (face) Silicone Rubber Foam Core Duct SwissAir 111 Database HRC (J/g-K) HIDDEN MATERIALS: Accident Investigation Pass OSU HRR Pass Bunsen Burner FLAMMABLEFLAMMABLE

22. Flammability (J/g-K) PP PE PS PET ABS PMMA Epoxy POM NYLON 66 PC PPO PU Polyarylate PPSF PPS PES PEI LCP's PAI PEK PEEK 0.1110100 Price of Plastic ($/lb) Phenolic (KAPTON) PI 1000 10 100 PVF (TEDLAR) Specialty Plastics Polysulfone PVC (rigid) FAA Research Plastics Common Plastics Current Aircraft FAA Goal FLAMMABILITY (HRC) RANKING BY COST Resin Plastic Flammable

23. CONCLUSIONS Heat release capacity HRC is a qualitative predictor of fire performance and flammability of aircraft materials Swelling, dripping, and barrier formation influence flame/fire tests but do not effect HRC.