development of a burnthrough test standard for thermal ... · pdf filedevelopment of a...
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Tim Marker
Development of a Burnthrough Test StandardFor Thermal Acoustic Insulation
FAA Technical Center
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Manchester 737 Accident, 1985
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Full-Scale Testing of Surplus Aircraft
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Burnthrough Entry Paths
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Full-Scale Burnthrough Test Rig
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Full-Scale Testing at FAA Tech Center
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0 60 120 180 240 300 360 420 480 540
Time (seconds)
Tem
pera
ture
(o F)
Aluminum Skin
0.42lb/ft3 Fiberglass with Metallized PVF Film
0.42 lb/ft3 Fiberglass with Polyimide Film
Fiberglass/Ceramic Paper with Metallized PVF Film
Rigid Polyimide Foam/Ceramic/QuartzelCeramic Fibers with Polyimide Film
Oxidized Polyacrylonitrile Fiber with Polyimide Film
Full-Scale Test Results Using Various Materials
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Laboratory Scale Test Development
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Finalized Test Frame
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Heat Flux Measurement on Backface of Samples
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Finalized Test Rig
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Lessons Learned
Method of Blanket Attachment
Proper Calibration, Set-up, and Operation of Test Equipment
Primary Factors Critical to Accurate Results:
Intake Air Velocity Measurement
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Initial Blanket Attachment Method
BurnthroughBurnthrough
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Overlapped Blanket Attachment Method
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Individual Calibration Rigs allow precise measurement of heat flux and temperature.
Arrangement of Calibrating Equipment
Data Collection Procedure
Heat Flux and Temperature measurements taken at precise time, for specific periodof time, to account for the build-up of soot.
Burner Hardware
Initially, a variety of internal components were possible. Standardization hasimproved inter-lab correlation considerably.
Test Method Improvements
Burner Set-up
The exact configuration of the internal components has a marked effect on theflame, and hence, the test results.
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Intake Air Velocity Measurement System
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0
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Failu
re T
ime
(Sec
onds
)
1:24
1:361:38
2:14
1:24 Avg
1:54 Avg
2000 ft/min 2100 ft/min 2200 ft/min
Full Scale Testsin 707
Lab Scale Tests with Burner.0
63-In
ch A
lcla
d +
3 La
yer A
eroc
or
.063
-Inch
Alc
lad
+ 4
Laye
r Aer
ocor
1:22 Avg
1:37 Avg
Correlation Using 6 GPH Burner (Full-Scale vs. Lab-Scale)
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Round Robin Testing
Objective:To identify and correct problems with proposed burnthrough test
equipment to ensure inter-lab agreement
Prove similarity of test equipment between labs through testing of identical samples
Participants:7 Domestic Labs, 3 European Labs
Status:5 round robins completed
Round Robin 6 in progress
Methodology:
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Round Robin I Material A Distribution
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4
6
8
10
12
Failure Range (Seconds)
Freq
uenc
y
0-15
16-3
0
31-4
5
46-6
0
61-7
5
76-9
0
91-1
05
106-
120
121-
135
136-
150
151-
165
166-
180
181-
195
196-
210
211-
225
346-
360
Avg = 102.9
Standard Dev = 68.8
Round Robin I Histogram
??
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Round Robin I Material A Modified Distribution
0
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8
10
12
Failure Range (Seconds)
Freq
uenc
y
0-15
16-3
0
31-4
5
46-6
0
61-7
5
76-9
0
91-1
05
106-
120
121-
135
136-
150
151-
165
Avg = 83.0
Standard Deviation = 28.0
Round Robin I Modified Histogram
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Round Robin III Histogram
0
5
10
15
20
25
30
Failure Range (Seconds)
Freq
uenc
y
1 to 10 11 to 20 21 to 30 31 to 40 41 to 50 51 to 60 61 to 70 71 to 80
Standard Deviation = 12 seconds
Average = 30 seconds
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Round Robin IV Histogram
0
5
10
15
20
25
Failure Range (Seconds)
Freq
uenc
y
Average = 28 seconds
Standard Deviation = 8 seconds
1 to 10 11 to 20 21 to 30 31 to 40 41 to 50 51 to 60
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Standard Deviation Trend
0
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20
30
40
50
60
70
80
90
Stan
dard
Dev
iatio
n (S
econ
ds)
0.60 lb/ft3 fiberglass
RRI RRII RRIII RRIV RRV
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Conclusion, Round Robins I Through V
Decreasing Standard Deviation Trend Result of:
Standardization of Test Burner/Apparatus
Standardization of Calibration and Test Procedures
Overall Increased Familiarization with Proposed Test Method
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Burnthrough Test Method Advisory Circular
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Burnthrough Test Method Advisory Circular
AC is neither mandatory nor regulatory.
AC describes acceptable means, but not the only means, for demonstratingcompliance.
The FAA will consider other methods of demonstrating compliance.
AC does not…
Change,
Create any additional,
Authorize changes in,
Permit deviations from,
…the regulatory requirements.
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Testing in Support of Advisory Circular
Conduct laboratory scale tests to investigate installation requirements
Overlap at vertical formers
Overlap at horizontal seams
Attachment Methods
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Typical Airframe Construction
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Gaps in insulation = potential fire entry route into cabin,
Insulation bags should completely cover the former,
Blanket Overlap at Vertical Former
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Blanket Overlap at Vertical Former
A minimum overlap of 2 inches should be used,
Overlaps greater than 2 inches will provide greater protection times.
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Blanket Overlap at Horizontal Joints
Minimum of 6 inches required to achieve satisfactory results,
Upper blanket should overlap lower blanket, W.R.T. fuselage interior,
Joints sealed with fire resistant tape, mechanical fastener, or other suitable means,
Overlapping of blankets not recommended at extreme fuselage bottom.
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Blanket Overlap at Horizontal Joints
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Horizontal Overlap Testing
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Attachments
Penetration of thermal acoustic liners should be avoided wherever possible,
Attachments that do not penetrate the liners are preferred (over-frame clips),
Attachments that provide good mechanical retention of thermal acoustic liners are more likely to provide good burnthrough protection.
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Through-Frame Attachments
Attachment methods that penetrate the insulation bag should be fire resistant,
Attachment pitch should be maximum of 14 inches,
Attachments should be installed as far away from skin as possible (min 1 inch).
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Over-Frame Attachments
Definition: Attachments that do not penetrate the frame, but provide attachment for the insulation bags by clipping them over the top of the frame. The material of such clipsand their pitch should provide good retention of the thermal acoustic liners. A maximumpitch of 14 inches for these attachments has been demonstrated to be acceptable.
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Other Thermal Acoustic Insulation Concepts
The oil burner test described in Appendix F, part VII to part 25 is intended torepresent the temperature and heat flux typical of a post crash fire. However, the scale of the test method does not replicate the scale of an actual fire. In addition, the test stand incorporates steel components to facilitate repeat testing.
It is therefore not necessarily adequate to simply incorporate a novel featureor design concept into the test burner stand to verify its acceptability. In some cases, larger scale testing will be required to support development of specialconditions, and in other cases the test burner may be acceptable with slightmodification to the sample holder (aluminum former & stringers).
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Other Material Concepts
The Advisory Circular assumes an encapsulated batting concept with respectto substantiation of installation details. Other concepts, such as foam blocksor spray-on applications, have not been investigated to the same extent, andreliable substantiation methods for installation have not been developed.
It would therefore be necessary to conduct realistic testing on these types ofmaterials in order to establish guidance for their installation. Specifics regard-ing the amount of overlap, for example, are likely to be different.
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Other Means of Attachment
Methods of attachment that vary significantly from those typically usedwill require substantiation with more representative fixturing. For example,a hook and pile type attachment would require substantiation by test, butcould probably be accomplished using the test burner, with appropriatemodification to the sample holder.
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Modification of the Test Fixture
If the test fixture needs to be modified in order to generate meaningful test data,the existing vertical steel former is replaced with an aluminum former. Similarly,two of the steel horizontal stringers are replaced with aluminum stringers.
This methodology allows the aluminum members to melt and fail with therealism of an actual aircraft fuselage during a postcrash fire scenario. Underthese conditions, not only are the blanket materials being tested, but ratherthe ability of the insulation system at preventing flame penetration is examined.
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Steel TestSample Frame
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ModifiedSample Frame
w/Aluminum Members
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Modified Test Sample Frame
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Modified Test Frame w/Aluminum Members
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Acceptable Installation Approaches
The following 2 schematics are representations of systems that have been testedusing actual aircraft structure and found to satisfy the requirement. Theseschemes are suitable for demonstration in the test rig, as defined in Appendix F,part VII, to part 25. Variations from the representations shown that would makethe installation more critical (for example, increased fastener pitch) should beassessed using the fixture modification described previously.
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Combination Fiberglass/Replacement Batting System
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Barrier Material Used in Conjunction With Fiberglass
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Future Considerations
Complete present round robin test series; analyze data
Development of a “no-moving-parts” intake air measurement system
Continue visiting laboratories to observe operation of test equipment
Development of a standardized burner for this and other FAA tests
Continue lab-scale testing in support of advisory circular
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The Fourth Triennial The Fourth Triennial The Fourth Triennial International Aircraft Fire and Cabin Safety International Aircraft Fire and Cabin Safety International Aircraft Fire and Cabin Safety Research ConferenceResearch ConferenceResearch Conference