1. 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

2. International Materials Fire Test Working Group October 21, 2009 2 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

3. International Materials Fire Test Working Group October 21, 2009 3 Federal Aviation Administration ADHESIVES TASK GROUP 3M American Airlines Boeing Bombardier Bostik C&D Aerospace Dassault FAA Henkel

4. International Materials Fire Test Working Group October 21, 2009 4 Federal Aviation Administration INDUSTRY-PROPOSED METHODS OF COMPLIANCE FOR CERTIFICATION OF INTERIOR MATERIALS BONDED DETAILS 28 25.853(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?

5. International Materials Fire Test Working Group October 21, 2009 5 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?

6. International Materials Fire Test Working Group October 21, 2009 6 Federal Aviation Administration -10 0 10 20 30 40 50 60 70 -10 0 10 20 30 40 50 60 70 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 0.040.0800.120.160.200.240.28 OSU Peak HRR of 0.040  does not substantiate.080  - 0.16  EUROPLEX PPSU Clear Proposed range

7. International Materials Fire Test Working Group October 21, 2009 7 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

8. International Materials Fire Test Working Group October 21, 2009 8 Federal Aviation Administration 250300350400450500550 0 100 200 300 400 500 Heat Release Rate (J/g-K) Temperature (°C) cc hchc TpTp  Noncombustible Fraction (g/g) 800 850 THERMAL COMBUSTION PROPERTIES FROM MCC Peak Heat Release Rate = Heat Release Capacity (J/g-K) Total Heat Release (J/g)  Burning Temperature

9. International Materials Fire Test Working Group October 21, 2009 9 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 0.1 110100 Materials Cost* ($/lb) Phenolic KAPTON 1000 10 100 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

10. International Materials Fire Test Working Group October 21, 2009 10 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 0 0.2 0.4 0.6 0.8 1 020040060080010001200

11. International Materials Fire Test Working Group October 21, 2009 11 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.

12. International Materials Fire Test Working Group October 21, 2009 12 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

13. International Materials Fire Test Working Group October 21, 2009 13 Federal Aviation Administration 0 50 100 150 200 0100200300400500600700 (R = 0.8264) avg  pHRR , kW/m 2  c , J/g-K OSU PHRR (binned data) 101 RESINS AND PLASTICS) Maximum Heat Release Capacity from Curve Fit

14. International Materials Fire Test Working Group October 21, 2009 14 Federal Aviation Administration HRR  65 kW/m 2 = Pass = P HRR > 65 kW/m 2 = Fail = F pHRR 1 9 10 13 15 22 29 50 105 108 115 120 121 127 129 136 140 141 152 153 155 156 159 173 192 196 201 203 215 230 235 248 261 265 276 295 298 301 316 345 349 359 8 25 59 13 66 31 55 30 54 92 61 49 123 60 52 109 64 65 69 110 90 30 85 45 72 106 36 32 74 65 213 150 97 258 55 44 188 199 93 211 232 166 115 207 90 127 174 254 355 36 9/10 = 0.90 6/10 = 0.60 3/10 = 0.30 4/10 = 0.40 0/10 = 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 25.853 PPPPFPPPPFPPFPPFPPFFFPFPFFPPFPFFFFPPFFFFFFFFFPPPPFPPPPFPPFPPFPPFFFPFPFFPPFPFFFFPPFFFFFFFFF

15. International Materials Fire Test Working Group October 21, 2009 15 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 = 0.97 14 CFR 25 OSU PHRR (101 RESINS AND PLASTICS) Probability that pHRR  65 kW/m 2 0 0.2 0.4 0.6 0.8 1 0100200300400500600700 = 102 J/g-K

16. International Materials Fire Test Working Group October 21, 2009 16 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

17. International Materials Fire Test Working Group October 21, 2009 17 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

18. International Materials Fire Test Working Group October 21, 2009 18 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)

19. International Materials Fire Test Working Group October 21, 2009 19 Federal Aviation Administration 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 012345 1.5 mm Adhesive Layer 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 012345 1 mm Adhesive Layer 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 012345 0.5 mm Adhesive Layer HRR (arbitrary units) HR (arbitrary units) Time, min 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 012345 0.2 mm Adhesive Layer Time, min OSU HRRs of BONDED CONSTRUCTIONS (ThermaKin)