FAA/NASA Workshop on Composite Material Control Mark Freisthler Allen Fawcett Rod Osborne August 2002

2 FAA/NASA Workshop on Composite Material Control Boeing Material Qualification & Certification Philosophy Established Methods, Processes and Specifications that ensure the engineering material requirements of the design are met with a high degree of confidence and reliability

3 FAA/NASA Workshop on Composite Material Control General Boeing Requirements Any set of Material/Process Specifications must: 4Ensure the continued certification basis of a product 4Allow the product to be economically produced 4Permit limited modifications to account for local production conditions 4Be responsive to the company’s changing requirements

4 FAA/NASA Workshop on Composite Material Control What Industry Specifications Must Accomplish to Provide Value to Boeing ã Lower cost  Qualification/Certification of new materials  Lower production cost ã Faster implementation time ã Commonality of specifications, methods and processes, and database requirements ã Rapid response to user needs ã Enable global standardization of specification requirements

5 ã Documented controls must be established ã The intended use of product has been identified ã Level of certification documentation has been identified FAA/NASA Workshop on Composite Material Control Air Framer’s Considerations ã Any new manufacturing technology must have a stable and repeatable product

6 ã Overly conservative design values ã Inability to adapt to vendor unique circumstances ã Loss of product consistency over time ã Unknown variability of key mechanical properties FAA/NASA Workshop on Composite Material Control Air Framer’s Concerns

7 ã Design Values do not control a product, but reflect the control placed on the product ã The analytical tools used in design dictate the parameters for which Design Values are derived ã Design Values must reflect actual in-use conditions FAA/NASA Workshop on Composite Material Control Design Value Basics ã Design Values must reflect materials & processes actually used in production

Testing Requirements Methods & Allowables Material & Process Specifications Performance Goals FAA/JAA Regulations Criteria OR Premium Selection or Point Design Spec Controls and Allowables & Analysis Methods in Place Certification Requirements The more the materials and processes are under control and Methods & Allowables understood, the less testing is required for certification FAA/NASA Workshop on Composite Material Control Certification Balance 8

AB = =+ + Material SpecificationProcess Specification Material PurchasedManufacturing Processes Prediction of Material Behavior (Design Values) Prediction of Structural Behavior (Design Analysis) Published Design Manuals (Design Analysis & Allowables) Manufacturing Processes Material & Processing Standards Engineering Processes Engineering Requirements & Standards Product Certification Basis + Verification & Certification Tests Arrows Denote Delivery Tools (Paper and/or Electronic) FAA/NASA Workshop on Composite Material Control Product & Design Connection 9

10 End User Requirements The Proposed “Bridge” Material Supplier Industry Specification FAA/NASA Workshop on Composite Material Control Compatibility Between Internal and External Documentation Internal Process Specification Material Specification Process Used to Produce Test Parts DOT FAA AR-02 XX