Surrogate Testingand

Proposed Certification Procedures for Altered Interior Surfaces

Tim Marker

FAA Technical Center

-the difficulties associated with the fire test approval of renovatedmaterial systems,

-investigates the results of heat release and flammability tests conducted usingsurrogate materials produced by three independent manufacturers.

This report discusses:

“Heat Release and Flammability Testing of Surrogate Panels”

Problem: How to administer OSU or VBB certification tests on renovated cabin interiorsurfaces when appropriate test substrates are unavailable.

Objective: To determine if surrogate materials can be used as accurate HR and BLpredictors for in-service materials being renovated.

A substrate used in-place of existing interior panels for the purposes of conductingHR or VBB certification tests.

A substrate which has the same basic construction and build-up as the OEM Panel,with a comparable lay-up process during manufacture.

Honeycomb core thickness, number of pre-preg plies per side, and reinforcement mustbe identical to the in-service panel.

Surrogate Material:

Surrogate Test Panel Basic Construction

Paint/Decorative Laminate

Top-Facing 2-ply Fiberglass

Bottom-Facing 2-ply Fiberglass

Core: 0.50-inch Nomex Paper/Phenolic Resin

Test type Panel fabricator Finish type Finish fabricator Renovation Number of TestsH = Heat Release B (Boeing) P = Paint Q HSH Aerospace X = No Renovation (in parenthesis)

F = Flammability C (C&D Interiors) L = Dec Laminate R Boeing Y = PaintD (Skyline Prod) S Mankiewicz Z = Dec Laminate

T SchnellerU Boeing

Panel Description Code

Finish Q Finish R Finish S Finish T Finish UPanel B HBPQX (15) HBPRX (15) HBPSX (13) HBLTX (15) HBLUX (15)Panel C HCPQX (15) HCPRX (15) HCPSX (12) HCLTX (15) HCLUX (15)Panel D HDPQX (16) HDPRX (16) HDPSX (16) HDLTX (16) HDLUX (16)

Heat Release Test Matrix

Finish Q Finish R Finish S Finish T Finish UPanel B FBPQX (15) FBPRX (15) FBPSX (15) FBLTX (15) FBLUX (15)Panel C FCPQX (15) FCPRX (15) FCPSX (15) FCLTX (15) FCLUX (15)Panel D FDPQX (15) FDPRX (15) FDPSX (15) FDLTX (16) FDLUX (16)

Flammability Test Matrix

Panel Type Total HR (kW/m2)min Peak HRR (kW/m2)Panel B Baseline1 30.48 33.63Panel B Baseline2 29.89 32.52Panel B Baseline3 27.45 32.07

Average 29.27 32.74

Panel Type Total HR (kW/m2)min Peak HRR (kW/m2)Panel C Baseline1 35.23 31.27Panel C Baseline2 26.70 25.43Panel C Baseline3 32.13 28.39

Average 31.35 28.36

Panel Type Total HR (kW/m2)min Peak HRR (kW/m2)Panel D Baseline1 32.78 35.85Panel D Baseline2 26.07 28.98Panel D Baseline3 20.25 30.06

Average 26.37 31.63

Surrogate Testing

Baseline Panel Numerical Averages

Panel B Baseline

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Time (seconds)

Hea

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kW/m

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Run 1

Run 2

Run 3

Surrogate Testing

Panel C Baseline

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Run 1

Run 2

Run 3

Surrogate Testing

Panel D Baseline

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Time (seconds)

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Run 3

Surrogate Testing

Point-by-Point Average

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Time (seconds)

Hea

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B AVE

C AVE

D AVE

Baseline Comparison

Heat Release Average (Point-by-Point)

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Time (seconds)

Hea

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HBPQX AVE (15 TESTS)HCPQX AVE (15 TESTS)HDPQX AVE (12 TESTS)

Paint Q Comparison

Heat Release Average (Point-by-Point)

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Time (seconds)

Hea

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HBPRX AVE (15 TESTS)

HCPRX AVE (15 TESTS)

HDPRX AVE (12 TESTS)

Paint R Comparison

Heat Release Average (Point-by-Point)

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Time (seconds)

Hea

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(kW

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HBPSX AVE (13 TESTS)

HCPSX AVE (12 TESTS)

HDPSX AVE (11 TESTS)

Paint S Comparison

Heat Release Average (Point-by-Point)

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HBLTX AVE (15 TESTS)

HCLTX AVE (15 TESTS)

HDLTX AVE (15 TESTS)

Laminate T Comparison

Heat Release Average (Point-by-Point)

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HBLUX AVE (15 TESTS)

HCLUX AVE (15 TESTS)

HDLUX AVE (12 TESTS)

Laminate U Comparison

Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR

Panel B Average 29.27 32.74 37.23 35.55 7.95 2.81

Panel C Average 31.35 28.36 40.30 46.79 8.95 18.43

Panel D Average 26.37 31.63 39.90 46.61 13.54 14.98

Unfinished Finish Q Increase

Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR

Panel B Average 29.27 32.74 43.90 35.93 14.63 3.19

Panel C Average 31.35 28.36 40.05 35.40 8.69 7.03

Panel D Average 26.37 31.63 44.91 43.22 18.54 11.59

Unfinished Finish R Increase

Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR

Panel B Average 29.27 32.74 40.08 35.48 10.80 2.74

Panel C Average 31.35 28.36 32.89 35.31 1.54 6.94

Panel D Average 26.37 31.63 36.13 36.43 9.77 4.80

Unfinished Finish S Increase

Surrogate Testing Results

Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR

Panel B Average 29.27 32.74 40.01 36.31 10.74 3.57

Panel C Average 31.35 28.36 50.59 39.41 19.23 11.05

Panel D Average 26.37 31.63 41.30 39.29 14.93 7.66

Unfinished Finish T Increase

Total HR Peak HRR Total HR Peak HRR Total HR Peak HRR

Panel B Average 29.27 32.74 39.79 42.41 10.51 9.67

Panel C Average 31.35 28.36 47.82 36.24 16.46 7.88

Panel D Average 26.37 31.63 41.58 39.49 15.21 7.86

Unfinished Finish U Increase

Surrogate Testing Results

Conclusions

Normal fluctuations between different labs will only compound the inaccuracy of test results.

Unfinished surrogate panels did not produce nearly-identical HRR traces, but differentpeaks that occurred at different times.

HRR differences are compounded when various finishes are applied; these cases representtypical in-service situations likely to occur during certification testing of renovated interiors.

All tests were performed:

At one facility,

With one tester,

Based on a large number of replicate tests;

Conclusions (con’t)

Based on the above, it would be very difficult to adopt a standardized procedurein which renovated interiors could be certified using surrogate materials.

Expectation: The increase in HR caused by a particular paint or decorative should beindependent of the identity of the surrogate panel.

Result: HR increase not independent of surrogate identity

Proposed Methodology for Certifying Renovations/Alterations(65/65 interior)

Option 1: Use flat panel spares supplied by manufacturer of A/C

Option 2: Use Cut-out specimen from A/C TBM (To Be Modified)

Option 3: If the original HR information is available for the component TBM, and the HRR is:

Less than 35/35: Fabricate and use surrogate specimen with HRR NLT 40/40

Less than 45/45, but greater than 35/35: Fabricate and use surrogate specimen with HRR NLT 50/50

Less than 55/55, but greater than 45/45: Fabricate and use surrogate specimen with HRR NLT 60/60

Greater than 55/55: Fabricate and use surrogate specimen with HRR NLT 63/63

*note: surrogate specimen must mimic the interior component TBM in every way, including core type,resin type, and thickness and number of pre-preg plies, plus any/all finishes such as paint or decorative.

*note: if original HR information is not available, this approach cannot be utilized.

Proposed Methodology for Certifying Renovations/Alterations(Pre 65/65 interior)

Option 1: Use flat panel spares supplied by manufacturer of A/C

Option 2: Use Cut-out specimen from A/C TBM (To Be Modified)

Option 3: If the original 60sec VBB information is available for the component TBM, and the BL is:

*note: surrogate specimen must mimic the interior component TBM in every way, including core type,resin type, and thickness and number of pre-preg plies, plus any/all finishes such as paint or decorative.

*note: if original 60sec VBB information is not available, then a surrogate specimen with BL NLT 5.5 inches may be used

Less than 1 inch: Fabricate and use surrogate specimen with BL NLT 1.5 inches

Less than 2 inches, but greater than 1 inch: Fabricate and use surrogate specimen with BL NLT 2.5 inches

Less than 3 inches, but greater than 2 inches: Fabricate and use surrogate specimen with BL NLT 3.5 inches

Less than 4 inches, but greater than 3 inches: Fabricate and use surrogate specimen with BL NLT 4.5 inches

Less than 6 inches, but greater than 4 inches: Fabricate and use surrogate specimen with BL NLT 5.5 inches