federal aviation international aircraft administration ......dress cover installed over new back...
TRANSCRIPT
Presented to:
By:
Date:
Federal AviationAdministration
International Aircraft Materials Fire Test
Working Group
Update on Flammability Testing of Magnesium
Alloy Components
IAMFT WG, Cologne, Germany
Tim Marker, FAA Technical Center
June 23, 2010
2 2Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Proposed Mag-Alloy Testing at FAA Tech Center
Method: Conduct (several?) baseline tests using OEM aluminum-framed triple seats with FBseat cushions. Tests will simulate a post-crash fire with fuselage rupture, allowing externalfire to directly impact the cabin materials.
Then…
Conduct additional tests in an identical fashion using mag-alloy in the construction of theprimary seat components. External fire permitted to burn for 5 minutes, then internal firepermitted to burn for 5 additional minutes before applying water.
Outcome: Determine if the use of mag-alloy poses additional hazard during entire 10-minute event
3 3Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Primary Seat Components
Spreader
Cross Tube
Leg
4 4Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Full-Scale Test Apparatus
5 5Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Initial 2 Baseline Tests Highlighted Seat Back Flammability
6 6Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Back Rest Construction of B/E 990 Seats
7 7Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Executive Decision to Conduct 3rd Baseline
Procure Additional 990 Seats, fabricate new seat backs
Target is 4 to 4 min 30 sec flashover
Application of water at set time for all remaining tests
Additional thermocouples in seat frames
Additional camera that will not become obscured during test
Conduct lab-scale oil burner testing of seat cushions used in testing
8 8Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
New Seat Back Frame Design2024 alum box frame, 0.75-inch by 1.5 inch
9 9Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
New Fire Hardened Foam for Seat Back
Foam supplied by Chestnut Ridge Seat-back frame built in house
10 10Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
New Fire Hardened Foam for Seat Back
11 11Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
New Seat Back
12 12Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
New Back Frame Installed
13 13Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Mass Production of Seat Back Frames
Aluminum back pan
14 14Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Dress Cover Installed Over New Back Frame
Dress covers supplied by Preferred Aviation, Miami
Aluminum front pan
15 15Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Seat ThermocouplesAdditional thermocouples installed in seat leg frames
16 16Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Application of Water Post-Testwater applied at end of all tests (not just magnesium), for similarity
17 17Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Additional ‘unobscurable’ video camera used for accurate application of water post test
Camera Location
18 18Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test Configuration
19 19Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test Results
20 20Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test Results
21 21Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test Results
22 22Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test Results
23 23Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test Results
24 24Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Baseline 3 Test ResultSummary of Findings
Incapacitation reached in 4 min 10 sec at forward location
Pan fire extinguished at 5 minutes using AFFF
Seat bottom cushions on port side heavily involved in fire
Increased melting of primary seat structure compared to previousbaseline tests
Seat backs (cushions, covers, plastics) mostly consumed on port side;largely intact on starboard side
Interior fire extinguished at 10 minutes using water
25 25Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Questions on Baseline Full-Scale Testing?
26 26Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Mag-Alloy Full-Scale Testing
•WE-43 (good-performing material)
•AZ-31 (poor-performing material)
•WE-43 in primary + back frame + baggage bar
27 27Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 Test Configuration
28 28Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 Test Configuration
29 29Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 Test Results
30 30Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 Test Results
31 31Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 Test Results
32 32Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 Test ResultSummary of Findings
Incapacitation reached in 4 min 38 sec at forward location
Pan fire extinguished at 5 minutes using AFFF
Seat bottom cushions on port side heavily involved in fire
Increased melting of primary seat structure compared to baseline 3 test
Seat backs (cushions, covers, plastics) mostly consumed on port side;largely intact on starboard side
Interior fire extinguished at 10 minutes using water
33 33Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
AZ-31 Test Configuration
34 34Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
AZ-31 Test Configuration
35 35Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
AZ-31 Test Results
36 36Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
AZ-31 Test ResultSummary of Findings
Incapacitation reached in 4 min 33 sec at forward location
Pan fire extinguished at 5 minutes using AFFF
Seat bottom cushions on port side heavily involved in fire
Increased melting of primary seat structure compared to baseline 3 test
Seat backs (cushions, covers, plastics) mostly consumed on port side;largely intact on starboard side
Interior fire extinguished at 10 minutes using water
37 37Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Test ComparisonTemperature 4' to 5' in Forward Cabin
0
100
200
300
400
500
600
0 60 120 180 240 300 360 420 480 540 600 660
Time (seconds)
Tem
pera
ture
(o F)
BL3 FWD Tree 4'BL3 FWD Tree 5'WE-43 FWD Tree 4'WE-43 FWD Tree 5'AZ-31 FWD Tree 4'AZ-31 FWD Tree 5'
Pan
Ext
ingu
ishe
d
Cab
in E
xtin
guis
hed
38 38Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Test ComparisonCarbon Monoxide at Forward Cabin
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 60 120 180 240 300 360 420 480 540 600 660
Time (Seconds)
CO
Con
cent
ratio
n (%
)
CO Fwd 5'6"BL3 CO Fwd 3'6"WE-43 CO Fwd 5'6"WE-43 CO Fwd 3'6" AZ-31 CO Fwd 5'6"AZ-31 CO Fwd 3'6"
Pan
Ext
ingu
ishe
d
Cab
in E
xtin
guis
hed
39 39Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
FED Comparison at Forward Station
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 60 120 180 240 300 360
Time (Seconds)
Frac
tiona
l Eff
ectiv
e D
ose
FED Fwd 66" (BL3)FED Fwd 66" (WE43)FED Fwd 66" (AZ-31)
250 sec
273 sec
278 sec
40 40Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
FED Comparison at Mid Station
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 60 120 180 240 300 360
Time (Seconds)
Frac
tiona
l Eff
ectiv
e D
ose
FED Mid 66" (BL3)FED Mid 66" (WE43)FED Mid 66" (AZ-31)
148 sec165
169 sec
41 41Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Conducted test with seats using WE-43 extrusions in back frame and
baggage bar on 4/20/10
Additional Full-Scale Tests (since last meeting)
Conducted test with seats using WE-43 extrusions in back frame and
baggage bar on 5/13/10 (repeat)
42 42Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 All-Mag Test
43 43Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 All-Mag Test
44 44Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
WE-43 All-Mag Test
45 45Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
All-Mag Repeat Test
46 46Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
All-Mag Repeat Test
47 47Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
All-Mag Repeat Test
48 48Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Summary of Full-Scale Testing
Incapacitation results very similar for baseline and mag-alloy tests
Noticeable difficulty extinguishing burning mag-alloy during AZ-31 test
Slight flashing of burning mag-alloy during water application for WE-43 test
For BL3, and mag-alloy tests, pan fire extinguished at 5 min, water applied at 10
•slightly better for mag-alloys at forward location
•slightly worse for mag-alloys at mid location
•More severe fire condition caused more rapid incapacitation during
“all-mag” tests
49 49Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Next Steps
Lab test development??
Comparison of all test results, study data, generate report
50 50Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Test Method Development
51 51Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Test Method Development
52 52Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Test Method DevelopmentItems to Consider…
Thermal Insult•Duration•Size•Intensity
Test Sample•Size•Geometry•Edge Effects?
Test Parameters•Melting Time
•After Flame Time•Weight Loss
53 53Federal AviationAdministration
Update on Flammability Testing of Magnesium Alloy ComponentsJune 23, 2010
Future Considerations
All full-scale test results would help define an appropriatelab-scale test method or methods, which is the primarygoal of the research.
Although post crash full-scale test results will help in determining the safe application of magnesium in seat frames, other scenarios and testing will also be used.
If magnesium alloys are determined safe for use in seat frames, a representative lab test/tests will be developed.