Guidelines and Guidelines and Recommendations for the Recommendations for the Development of a Material Development of a Material

Specification forSpecification forCarbon Fiber Reinforced Liquid Carbon Fiber Reinforced Liquid

Resin Molded MaterialsResin Molded Materials

Gregg BoguckiGregg Bogucki

FAA Workshop on Key Characteristics for Advanced FAA Workshop on Key Characteristics for Advanced Material ControlMaterial Control

Chicago, ILChicago, ILSeptember 16, 2003September 16, 2003

22

Document DevelopmentDocument Development

• TeamTeam– Will McCarvillWill McCarvill Curtis DaviesCurtis Davies– Stephen WardStephen Ward Larry IlcewiczLarry Ilcewicz– Larry Gintert Larry Gintert John TomblinJohn Tomblin– John BayldonJohn Bayldon– Gregg BoguckiGregg Bogucki

• Time LineTime Line– First Draft:First Draft: September 2003September 2003– FAA Workshop:FAA Workshop: September 2003September 2003– Rework Draft with Workshop Input:Rework Draft with Workshop Input: September - October September - October

20032003– Final Draft to FAA:Final Draft to FAA: November 2003November 2003– Release by FAA:Release by FAA: TBDTBD

33

IntroductionIntroduction

• Incorporated the philosophy developed for the Incorporated the philosophy developed for the uni-directional tape and fabric documents.uni-directional tape and fabric documents.

• Fabric selected as preform product.Fabric selected as preform product.

• Familiar industry standards for manufacture, Familiar industry standards for manufacture, design, and use.design, and use.

• Addresses common themes such as resin mixing, Addresses common themes such as resin mixing, combining resin with preform, and testing.combining resin with preform, and testing.

44

Document OutlineDocument OutlineExecutive SummaryExecutive Summary1.1. Introduction.Introduction.

1.11.1 Objective.Objective.1.21.2 Background.Background.1.31.3 Related DocumentsRelated Documents1.41.4 Certification Process.Certification Process.

2.2. Liquid Resin Molding Process and MaterialsLiquid Resin Molding Process and Materials2.12.1 Liquid Molding ProcessLiquid Molding Process2.22.2 Liquid Molding MaterialsLiquid Molding Materials

3.3. Development of Material Controls.Development of Material Controls. 3.13.1 Industry Material Specification.Industry Material Specification.3.23.2 Part Producer Material Specification.Part Producer Material Specification.3.33.3 Part Producer Responsibilities for Material Use in Part Producer Responsibilities for Material Use in

Structural DesignStructural Design3.43.4 Material Qualification Process When Using an Industry Material Qualification Process When Using an Industry

Material Specification.Material Specification.3.53.5 Material Qualification Process When Using an Part Material Qualification Process When Using an Part

producer Material Specificationproducer Material Specification

55

Document OutlineDocument Outline4.4. Qualification RequirementsQualification Requirements

4.14.1 Initial Material QualificationInitial Material Qualification4.24.2 Minimum Level Of TestingMinimum Level Of Testing4.34.3 Equivalency Baseline EnhancementEquivalency Baseline Enhancement4.44.4 Additional Characterization Testing For Specific Design Additional Characterization Testing For Specific Design ApplicationsApplications4.54.5 Supplier Site QualificationSupplier Site Qualification4.64.6 Changes To Qualified MaterialsChanges To Qualified Materials

5.5. Recommended LRM Specification StructureRecommended LRM Specification Structure5.15.1 Recommended Specification StructureRecommended Specification Structure5.25.2 Sectional Arrangement of SpecificationSectional Arrangement of Specification

6.6. Guidelines for Sections of a Resin Material Procurement SpecificationGuidelines for Sections of a Resin Material Procurement Specification7.7. Guidelines for Sections of a Fabric Material Procurement Guidelines for Sections of a Fabric Material Procurement

SpecificationSpecification8.8. Guidelines for Sections of a Material Acceptance Specification for Guidelines for Sections of a Material Acceptance Specification for

Composite PartsComposite Parts

66

Generic Liquid Resin Molding Generic Liquid Resin Molding Process FlowProcess Flow

77

Liquid Resin Molding ProcessLiquid Resin Molding ProcessTooling OptionsTooling Options

All surfaces controlled by rigid tooling

Only a portion of the part controlled by rigid tooling

Closed-cavity Mold Open-cavity Mold

All surfaces controlled by rigid tooling

Only a portion of the part controlled by rigid tooling

Closed-cavity Mold Open-cavity Mold

88

LRM Material FlowLRM Material Flow

•Reactive Resin Material•Non-Reactive Reinforcement Material•Assembled Material (Preform)•Consumable & Ancillary Materials

Possible to combine different resin batcheswith different fabric batches. Do we need toTest all possible combinations?

99

Test Approach BasedOn Risk.

1010

Material Control ApproachMaterial Control Approach

• One approach for material control of liquid resin One approach for material control of liquid resin molded parts is the use of material procurement molded parts is the use of material procurement specifications for the constituent materials (resin specifications for the constituent materials (resin and reinforcement) in combination with an a and reinforcement) in combination with an a material acceptance specification for the cured material acceptance specification for the cured parts. parts.

• The constituent materials are controlled through The constituent materials are controlled through material procurement specifications. material procurement specifications.

• The combined system is then controlled at the The combined system is then controlled at the cured composite assembly (resin combined with cured composite assembly (resin combined with reinforcement) through an acceptance reinforcement) through an acceptance specification by the purchaser part producer.specification by the purchaser part producer.

• This same document would can define the process This same document would can define the process for qualifying the material system. for qualifying the material system.

1111

Let the Material Drive the Let the Material Drive the SpecificationSpecification

Traditional ApproachTraditional Approach • Users develop a specification and material suppliers strive to Users develop a specification and material suppliers strive to

provide materials that meet the requirements. The same provide materials that meet the requirements. The same material is be qualified to many different specifications.material is be qualified to many different specifications.

• Limited number of batches qualifies a material to the user Limited number of batches qualifies a material to the user specification. The qualification tests are rarely run again.specification. The qualification tests are rarely run again.

• This approach leads to:This approach leads to:– A ‘test to pass’ minimum specification values mentality.A ‘test to pass’ minimum specification values mentality.– A lack of knowing what the true material variability is.A lack of knowing what the true material variability is.– Barn door manufacturing process limits to ensure the Barn door manufacturing process limits to ensure the

supplier had plenty of room to make material that passes.supplier had plenty of room to make material that passes.– Preaching, but not practicing, SPC.Preaching, but not practicing, SPC.– A failure to continually add to the qualification database and A failure to continually add to the qualification database and

keep test methods current.keep test methods current.– Scary re-qualifications.Scary re-qualifications.

1212

Let the Material Drive the Let the Material Drive the SpecificationSpecification

Shared Database ApproachShared Database Approach• Material supplier can also establish the database for an Material supplier can also establish the database for an

industry material and define the specification.industry material and define the specification.• Establish preliminary targets and ranges for material Establish preliminary targets and ranges for material

characteristics and properties in a limited ‘qualification’:characteristics and properties in a limited ‘qualification’:– Acceptance testing for certification and purchaseAcceptance testing for certification and purchase– Minimum testing for database.Minimum testing for database.– Additional testing to show material is acceptable for Additional testing to show material is acceptable for

intended use.intended use.• Database should be augmented on an ongoing basis:Database should be augmented on an ongoing basis:

– Establish true material variability.Establish true material variability.– Allow for SPC monitoring and control.Allow for SPC monitoring and control.– No shocks or surprises when a change happens.No shocks or surprises when a change happens.– Spec acceptance limits are unique for EACH material and Spec acceptance limits are unique for EACH material and

based on properties of that material – NO requirements based on properties of that material – NO requirements based on the minimum of a bunch of materials!based on the minimum of a bunch of materials!

1313

Encourage Use of Industry Standards Encourage Use of Industry Standards for Definitions of Terms, Test Methods, for Definitions of Terms, Test Methods,

and Change Leveland Change Level

• Test methods can come from SACMA and Test methods can come from SACMA and ASTM.ASTM.

• Definitions can come from MIL-HDBK-17.Definitions can come from MIL-HDBK-17.

• Methods for calculating specification Methods for calculating specification limits are found in DOT/FAA AR/00-47.limits are found in DOT/FAA AR/00-47.

• Allowables can be calculated from Allowables can be calculated from procedures found in MIL-HDBK-17.procedures found in MIL-HDBK-17.

1414

Development of Material Controls: Development of Material Controls: Industry Material Industry Material

Specification/QualificationSpecification/Qualification• Supplier will:Supplier will:

– Develop new material or make an industry specification Develop new material or make an industry specification for an old material.for an old material.

– Stabilize the production process.Stabilize the production process.– Establish the cure cycle to be used for the qualification Establish the cure cycle to be used for the qualification

database.database.– Perform minimum qualification tests per FAA approval and Perform minimum qualification tests per FAA approval and

witnessing.witnessing.– Develop statistical material control limits and allowable Develop statistical material control limits and allowable

values.values.– Submit data to an industry committee for approval.Submit data to an industry committee for approval.

• Part Fabricator / End-user will:Part Fabricator / End-user will:– Demonstrate equivalency to industry-approved data base Demonstrate equivalency to industry-approved data base

and use material allowables.and use material allowables.– End-user will perform design verification and certification End-user will perform design verification and certification

tests.tests.

1515

Development of Material Controls: Development of Material Controls: Part Fabricator / End-User Material Part Fabricator / End-User Material

Specification/QualificationSpecification/Qualification• Supplier will:Supplier will:

– Develop new material or supply an old material.Develop new material or supply an old material.– Stabilize the production process.Stabilize the production process.– Establish the cure cycle to be used for the qualification Establish the cure cycle to be used for the qualification

database.database.– Supply to an End-userSupply to an End-user

• The Part Fabricator / End-user will:The Part Fabricator / End-user will:– Perform minimum qualification tests per FAA approval Perform minimum qualification tests per FAA approval

and witnessing.and witnessing.– Develop statistical material control limits and allowable Develop statistical material control limits and allowable

values.values.– Perform design verification and certification tests.Perform design verification and certification tests.

1616

Development of Material Controls: Development of Material Controls: Part Fabricator / End-User Part Fabricator / End-User

ResponsibilitiesResponsibilities

• Qualify the material for use in a specific Qualify the material for use in a specific application.application.

• Validate design details.Validate design details.

• If an Industry Material Specification is selected, If an Industry Material Specification is selected, conduct tests to show statistical equivalency to conduct tests to show statistical equivalency to original property database.original property database.

• Conduct tests to validate any deviations from Conduct tests to validate any deviations from baseline cure cycle.baseline cure cycle.

• Conduct acceptance testing to receive material to Conduct acceptance testing to receive material to industry or end-user material specificationindustry or end-user material specification

1717

Technical Requirements: Batch Technical Requirements: Batch DefinitionsDefinitions

• FiberFiber - made in one continuous run under the same - made in one continuous run under the same process conditions using one to three precursor process conditions using one to three precursor batches with up to a 72 hour interruption.batches with up to a 72 hour interruption.

• FabricFabric - woven from up to three batches of fiber - woven from up to three batches of fiber without an interruption greater than 72 hours.without an interruption greater than 72 hours.

• ResinResin - depends on mixing process but typically - depends on mixing process but typically means that the same batches of raw materials are means that the same batches of raw materials are used and the actual mix process is not interrupted. used and the actual mix process is not interrupted. Some blending of individual raw material batches is Some blending of individual raw material batches is permitted as long as the overall resin has the same permitted as long as the overall resin has the same mix ratio of the specific ingredients.mix ratio of the specific ingredients.

1818

Establishing and Following a Process Establishing and Following a Process Control Document is Critical to The Control Document is Critical to The

New PhilosophyNew Philosophy• The PCD should document all aspects of the material The PCD should document all aspects of the material

fabrication.fabrication.– Raw materials.Raw materials.– Key process parameters.Key process parameters.– SPC procedures and requirements.SPC procedures and requirements.

• Process parameter targets and ranges should be Process parameter targets and ranges should be determined by engineering trials and should be re-determined by engineering trials and should be re-evaluated on an ongoing basis like the material property evaluated on an ongoing basis like the material property database.database.

• The PCD is maintained by the material supplier and should The PCD is maintained by the material supplier and should be made available for review by the end-users and be made available for review by the end-users and certification agencies.certification agencies.

1919

Recommend Minimum Testing Recommend Minimum Testing RequirementsRequirements

so the PCD is Data Drivenso the PCD is Data Driven• It is expected that behind the process limits and in process tests It is expected that behind the process limits and in process tests

is a body of data and an understanding of the material and the is a body of data and an understanding of the material and the effects of the various processing steps upon the material.effects of the various processing steps upon the material.

• Selection of appropriate test methods and generation of data will Selection of appropriate test methods and generation of data will result in a database that can ensure the sale of consistent result in a database that can ensure the sale of consistent material and a reservoir of knowledge to aid problem solving and material and a reservoir of knowledge to aid problem solving and identify material changes.identify material changes.

• Recommended that tolerances be stacked and the resulting Recommended that tolerances be stacked and the resulting material evaluated to demonstrate that its cure characteristics material evaluated to demonstrate that its cure characteristics and mechanical properties are still within statistical limits.and mechanical properties are still within statistical limits.

• Effects of stacked tolerances on handling characteristics such as Effects of stacked tolerances on handling characteristics such as tack and drape, and cured composite quality, should be tack and drape, and cured composite quality, should be evaluated.evaluated.

2020

Technical Requirements: Neat Resin Technical Requirements: Neat Resin PropertiesProperties

• Recommended that the supplier develop a database of resin Recommended that the supplier develop a database of resin properties.properties.

• Although resin properties are not used in design, the database will Although resin properties are not used in design, the database will enable processes to be developed with an fundamental knowledge enable processes to be developed with an fundamental knowledge and understanding of the resin composition and reactivity.and understanding of the resin composition and reactivity.

• Test methods include, but are not limited to:Test methods include, but are not limited to:– DensityDensity - High performance liquid chromatography - High performance liquid chromatography– ViscosityViscosity - Rheology - Rheology– Gel timeGel time - Reaction kinetics - Reaction kinetics– Infrared spectroscopyInfrared spectroscopy

• Tests will have to be modified to deal with solvated resins as Tests will have to be modified to deal with solvated resins as solvents have a profound effect on the rheology of resin.solvents have a profound effect on the rheology of resin.

2121

Technical Requirements: Technical Requirements: Carbon Fiber and Fabric PropertiesCarbon Fiber and Fabric Properties

• Carbon fiber must be purchased to a specification tied to Carbon fiber must be purchased to a specification tied to either the prepreg or fabric specification.either the prepreg or fabric specification.

• Not only should mechanical properties such as tensile Not only should mechanical properties such as tensile strength, modulus and elongation be part of the batch strength, modulus and elongation be part of the batch acceptance testing, acceptance testing, but the size type and level must be specified as well as tow but the size type and level must be specified as well as tow bundle count and twist.bundle count and twist.

• Fiber specification should define the average values and Fiber specification should define the average values and ranges for all critical mechanical and physical ranges for all critical mechanical and physical

• Fabric specification should establish the critical fiber Fabric specification should establish the critical fiber properties, fabric areal weight and fabric style.properties, fabric areal weight and fabric style.

• Physical characteristics such as width, tracer type and spacing, Physical characteristics such as width, tracer type and spacing, alignment, openness, yarn count per inch should be defined.alignment, openness, yarn count per inch should be defined.

2222

Technical Requirements: Technical Requirements: Cured Composite Material Cured Composite Material

RequirementsRequirements

• Document is not a typical material procurement Document is not a typical material procurement document, rather it defines the qualified constituent document, rather it defines the qualified constituent materials, and the cured material property requirements materials, and the cured material property requirements that the part producer themselves are required to that the part producer themselves are required to demonstrate adherence to for each production partdemonstrate adherence to for each production part

• Test panels are to be fabricated using the same processes Test panels are to be fabricated using the same processes used to develop qualification and design data.used to develop qualification and design data.

2323

Technical Requirements: Technical Requirements: Recommended Mechanical Property Recommended Mechanical Property

Test MatricesTest Matrices• Minimum setMinimum set

– Unidirectional and cross-ply strength and modulusUnidirectional and cross-ply strength and modulus– Batch acceptance testsBatch acceptance tests

• RT [90] (fill) tensionRT [90] (fill) tension

• Hot [90] (fill) compressionHot [90] (fill) compression

• RT SB shearRT SB shear

• Additional for general applicationsAdditional for general applications– Open hole tension, compression strengthOpen hole tension, compression strength

• Additional for expanded databaseAdditional for expanded database– Market/application drivenMarket/application driven

• Essentially the same as recommended for tape prepreg Essentially the same as recommended for tape prepreg materialsmaterials

2424

Technical Requirements: Minimum Set Technical Requirements: Minimum Set of Mechanical Propertiesof Mechanical Properties

Lay-up Name

Ply Lay-up Sequence (starting from toolside)

Recommended Thickness Range for Selecting ‘n’

(inches) 1. Warp Tension [ 0* ]n 0.060 to 0.100 2. Warp Compression [ 0* ]n 0.100 to 0.150 3. Fill Tension [ 90* ]n 0.060 to 0.100 4. Fill Compression [ 90* ]n 0.100 to 0.150 5. 45 Shear [ 45/-45/45/-45 // -45*/45*/-45*/45* ] 6. Warp Interlaminar [ 0* ]n 0.240 to 0.260 7. Quasi Laminate [ (45/0/-45/0)n // (0*/-45*/0*/45*)n ] 0.100 to 0.150 8. Soft Laminate [ (45/-45/0/45/-45)n // (-45*/45*/0*/-45*/45*) ] 0.100 to 0.150 9. Hard Laminate [ (0/0/45/0/0)n // (0*/0*/45*/0*/0*) ] 0.100 to 0.150 10. Warp Sandwich [ 0*/0*/ core /0/0 ] (warp face next to core) 11. Fill Sandwich [ 90*/90*/ core /90/90 ] (warp face next to core) 12. Quasi Sandwich [ 45*/0*/ core /0/45 ] (warp face next to core) 13. Warp Toughness [ 0* ]n 0.120 to 0.200 14. Quasi CAI [ (45/0/-45/0)n // (0*/-45*/0*/45*)n ] 0.140 to 0.200

Recommended Layups:

2525

Technical Requirements: Minimum Set Technical Requirements: Minimum Set of Mechanical Propertiesof Mechanical Properties

No. of Batches x No. of Panels x No. of Tests/Batch/Panels

Test Temperature/Moisture Condition

Layup (see Table

5A) Test Type and

Direction Property

Lowest Temperature/

Ambient 70F/

Ambient

Highest Temperature/

Ambient

Highest Temperature/

Wet

1. Warp Tension

0 (Warp)Tension ASTM D 3039

Ultimate Strength and Modulus

3 x 2 x 3 3 x 2 x 3 2 1 x 2 x 3

2. Warp Compression

0 (Warp) Compression ASTM D 6641

Ultimate Strength and Modulus

3 x 2 x 3 3 x 2 x 3 2 1 x 2 x 3 1 x 2 x 3

3. Fill Tension

90 (Fill) Tension ASTM D 3039

Ultimate Strength and Modulus

3 x 2 x 3 3 x 2 x 3 1 1 x 2 x 3 2 3 x 2 x 3

4. Fill Compression

90 (Fill) Compression ASTM D 6641

Ultimate Strength and Modulus

3 x 2 x 3 3 x 2 x 3 2 1 x 2 x 3 1 3 x 2 x 3

5. 45 Shear In-plane Shear ASTM D 3518

Ultimate Strength and Modulus

3 x 2 x 3 3 x 2 x 3 2 3 x 2 x 3 3 x 2 x 3

6. Warp Interlaminar

Short Beam Shear ASTM D 2344

Ultimate Strength

3 x 2 x 3 1

1 – Batch acceptance tests (see section 6.5) 2 – Equivalency baseline database tests (see section 5.6.2)

Recommended Test Matrix:

2626

Technical Requirements: Technical Requirements: Recommended Expanded Database Recommended Expanded Database

TestsTests• Quasi, hard, soft layups:Quasi, hard, soft layups:– Unnotched tension and compressionUnnotched tension and compression– Open hole tension and compressionOpen hole tension and compression– Filled hole tension and compressionFilled hole tension and compression– BearingBearing

• Interlaminar shearInterlaminar shear

• Sandwich flexure (unnotched, open hole, impacted)Sandwich flexure (unnotched, open hole, impacted)

• In-plane shear (solvent sensitivities)In-plane shear (solvent sensitivities)

• Fracture toughnessFracture toughness

• Laminate compression after impactLaminate compression after impact

• Open hole fatigueOpen hole fatigue

2727

Technical Requirements: Technical Requirements: Recommended Expanded Database Recommended Expanded Database

TestsTests• Generally critical environmental conditions shown with a Generally critical environmental conditions shown with a

• Portion of matrix shown below:Portion of matrix shown below: Test Temperature/Moisture Condition Layup

(see Table 5A)

Test Type and Direction Property

Lowest Temperature

/ Ambient 70F/

Ambient

Highest Temperature

/ Ambient

Highest Temperature

/ Wet

7. Quasi Laminate Unnotched Tension ASTM D3039

Ultimate Strength

8. Soft Laminate Unnotched Tension ASTM D3039

Ultimate Strength

9. Hard Laminate Unnotched Tension ASTM D3039

Ultimate Strength

7. Quasi Laminate Unnotched Compression

Ultimate Strength

8. Soft Laminate Unnotched Compression

Ultimate Strength

2828

Technical Requirements: QualificationTechnical Requirements: Qualification

• Initial material characterization (Qualification)Initial material characterization (Qualification)– Minimum of 3 prepreg batches (3 resin, 2 fiber batches)Minimum of 3 prepreg batches (3 resin, 2 fiber batches)– Use AGATE developed procedures for establishing Use AGATE developed procedures for establishing

acceptance limits and equivalency requirementsacceptance limits and equivalency requirements Max average, min average and min individuals for Max average, min average and min individuals for

strength properties.strength properties. Max and min average values for stiffness propertiesMax and min average values for stiffness properties Max and min average values for cured ply thickness, resin Max and min average values for cured ply thickness, resin

content, areal weight, Tg, etc.content, areal weight, Tg, etc. Max average values for volatile content, void content, etc.Max average values for volatile content, void content, etc.

– Acceptance Tests:Acceptance Tests:

• Fiber, resin, volatile contents; flow; HPLC; cured thicknessFiber, resin, volatile contents; flow; HPLC; cured thickness

• RT [90] (fill) tension, Hot [90] (fill) compression, RT SB RT [90] (fill) tension, Hot [90] (fill) compression, RT SB shearshear

2929

Technical Requirements: Expanded Technical Requirements: Expanded Batch TestingBatch Testing

• Recommends expanded batch testing:Recommends expanded batch testing:– Provide robust equivalency databaseProvide robust equivalency database– Ongoing validation of structural propertiesOngoing validation of structural properties– Reduce chances for “surprises” during re-qualifications,Reduce chances for “surprises” during re-qualifications,

equivalency demonstrationsequivalency demonstrations– Early detection of drift in properties so corrective action Early detection of drift in properties so corrective action

can be takencan be taken– Potential for higher allowablesPotential for higher allowables– Perform tests for 1Perform tests for 1stst 12 production batches 12 production batches

• Recalculate spec acceptance/equivalency Recalculate spec acceptance/equivalency requirementsrequirements

– If material in control, reduce to once every 30 batchesIf material in control, reduce to once every 30 batches• After 10 sets of data, recalculate spec requirementsAfter 10 sets of data, recalculate spec requirements

3030

Technical Requirements: Expanded Technical Requirements: Expanded Batch TestingBatch Testing

• Expanded batch testingExpanded batch testing(recommended tests for equivalency baseline (recommended tests for equivalency baseline database):database):– TgTg– RT [0] (warp) tension, compression strength, RT [0] (warp) tension, compression strength,

modulusmodulus– Hot [90] (fill) tension strength, modulusHot [90] (fill) tension strength, modulus– RT [90] (fill) compression strength, modulusRT [90] (fill) compression strength, modulus– RT In-plane shearRT In-plane shear– RT, Hot Open hole tension, compressionRT, Hot Open hole tension, compression

3131

Quality Assurance: Changes to Quality Assurance: Changes to Qualified MaterialsQualified Materials

• Expansion of AGATE equivalency proceduresExpansion of AGATE equivalency procedures

• Defines 5 levels of changeDefines 5 levels of change– Based on FAA draft composite material TSOBased on FAA draft composite material TSO– Recommends types of changes that apply to each Recommends types of changes that apply to each

levellevel

• Degree of FAA approval of each level of change is not Degree of FAA approval of each level of change is not covered in detail in these guidelines documentscovered in detail in these guidelines documents– Major changes effect material allowables or Major changes effect material allowables or

acceptance limits per 14 CFR 21.93acceptance limits per 14 CFR 21.93– Approval of minor and major changes covered in 14 Approval of minor and major changes covered in 14

CFR 21.95 and 21.97CFR 21.95 and 21.97

3232

Quality Assurance: A Clear Protocol for Quality Assurance: A Clear Protocol for Dealing With ChangeDealing With Change

• Level 0Level 0 (Minor Change) (Minor Change)– Change in ingredient name, company name, correction of typosChange in ingredient name, company name, correction of typos– No notification of end users is requiredNo notification of end users is required

• Level 1Level 1 (Minor Change) (Minor Change)– Changes to packaging materialsChanges to packaging materials– Alternate vendor for chemically and physically identical raw Alternate vendor for chemically and physically identical raw

materialsmaterials– Current end users are notified, but approval by end user not Current end users are notified, but approval by end user not

requiredrequired• Level 2Level 2 (Major Change) (Major Change)

– Change in resin ingredient supplier, change in resin ingredient Change in resin ingredient supplier, change in resin ingredient precursor, modifications of process equipment, addition of new precursor, modifications of process equipment, addition of new similar equipment.similar equipment.

– New source for chemically and physically similar raw materialsNew source for chemically and physically similar raw materials– Notify and obtain approval of current end usersNotify and obtain approval of current end users

3333

Quality Assurance: A Clear Protocol for Quality Assurance: A Clear Protocol for Dealing With ChangeDealing With Change

• Level 3Level 3 (Major Change) (Major Change)– Change in fiber manufacturing process, fiber size or finishChange in fiber manufacturing process, fiber size or finish– Change in resin chemistry, viscosity of resin componentsChange in resin chemistry, viscosity of resin components– Change in resin mixing, filming and prepregging equipment, Change in resin mixing, filming and prepregging equipment,

change in resin or fiber manufacturing site.change in resin or fiber manufacturing site.– Change in cure cycleChange in cure cycle– Full equivalency testing and end user approvalFull equivalency testing and end user approval

• Level 4Level 4 (Major Change) (Major Change)– Change in fiber type, areal weight, tow count, manufacturerChange in fiber type, areal weight, tow count, manufacturer– Change in fabric weaveChange in fabric weave– Change in resin formulation, large change in resin contentChange in resin formulation, large change in resin content– New product specificationNew product specification

3434

Quality Assurance: SPC Methods are Quality Assurance: SPC Methods are Key to Reducing VariabilityKey to Reducing Variability

• Recommends SPC for key characteristics and key process Recommends SPC for key characteristics and key process parametersparameters– KCs: batch acceptance testsKCs: batch acceptance tests– KPPs: resin mixing and fabric weaving parameters that have a KPPs: resin mixing and fabric weaving parameters that have a

significant influence on the KCssignificant influence on the KCs

• Determine prior to qualificationDetermine prior to qualification

• Document in PCDDocument in PCD– Control limits set based on natural variability of product and Control limits set based on natural variability of product and

processes.processes.– Data should be collected, plotted, analyzed and acted upon Data should be collected, plotted, analyzed and acted upon – Action should be taken based on standard criteria for non-Action should be taken based on standard criteria for non-

random variability and random variability and beforebefore data shows product is outside data shows product is outside the control limits.the control limits.

3535

Quality Assurance: Reduced TestingQuality Assurance: Reduced Testing

• Requires use of SPC to monitor:Requires use of SPC to monitor:– Resin Mixing & Fabric Weaving process (KPPs)Resin Mixing & Fabric Weaving process (KPPs)– Material properties (KCs) Material properties (KCs)

• Requires high levels of SPC control and capabilityRequires high levels of SPC control and capability– Demonstrated over minimum of several years Demonstrated over minimum of several years

of prepreg productionof prepreg production

• Requires approval of FAA and end-usersRequires approval of FAA and end-users

• Must be documented in the PCDMust be documented in the PCD

3636

Miscellaneous TopicsMiscellaneous Topics

• Product CertificationProduct Certification

• Test MethodsTest Methods

• Storage Life RevalidationStorage Life Revalidation

• Material Test MethodsMaterial Test Methods

• Material DistributorsMaterial Distributors

• GlossaryGlossary– General terms (from tape document)General terms (from tape document)– Fabric defect definitions and figuresFabric defect definitions and figures

Crease or wrinkle:

3737

Workshop Goals for LRM Materials Workshop Goals for LRM Materials DocumentDocument

• Comments, criticisms, and contributions from Comments, criticisms, and contributions from you.you.– The goal is to reduce cost to both suppliers and The goal is to reduce cost to both suppliers and

users while maintaining safety.users while maintaining safety.– Focus discussions on LRM material specific Focus discussions on LRM material specific

issues.issues.

• All input will be reviewed, discussed, and All input will be reviewed, discussed, and incorporated into the final document.incorporated into the final document.

• Thanks in advance for your help.Thanks in advance for your help.