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Surrogate Testing and Proposed Certification Procedures for Altered Interior Surfaces

Surrogate Testing and Proposed Certification Procedures for Altered Interior Surfaces. Tim Marker. FAA Technical Center. “Heat Release and Flammability Testing of Surrogate Panels”. This report discusses:. -the difficulties associated with the fire test approval of renovated

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Surrogate Testing and Proposed Certification Procedures for Altered Interior Surfaces

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  1. Surrogate Testing and Proposed Certification Procedures for Altered Interior Surfaces Tim Marker FAA Technical Center

  2. “Heat Release and Flammability Testing of Surrogate Panels” This report discusses: -the difficulties associated with the fire test approval of renovated material systems, -investigates the results of heat release and flammability tests conducted using surrogate materials produced by three independent manufacturers.

  3. Problem: How to administer OSU or VBB certification tests on renovated cabin interior surfaces when appropriate test substrates are unavailable. Objective: To determine if surrogate materials can be used as accurate HR and BL predictors for in-service materials being renovated. Surrogate Material: A substrate used in-place of existing interior panels for the purposes of conducting HR 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 must be identical to the in-service panel.

  4. Surrogate Test Panel Basic Construction Paint/Decorative Laminate Top-Facing 2-ply Fiberglass Core: 0.50-inch Nomex Paper/Phenolic Resin Bottom-Facing 2-ply Fiberglass

  5. Panel Description Code

  6. Heat Release Test Matrix

  7. Flammability Test Matrix

  8. Surrogate Testing Baseline Panel Numerical Averages

  9. Surrogate Testing

  10. Surrogate Testing

  11. Surrogate Testing

  12. Baseline Comparison

  13. Paint Q Comparison

  14. Paint R Comparison

  15. Paint S Comparison

  16. Laminate T Comparison

  17. Laminate U Comparison

  18. Surrogate Testing Results

  19. Surrogate Testing Results

  20. Conclusions Unfinished surrogate panels didnot produce nearly-identical HRR traces, but different peaks that occurred at different times. HRR differences are compounded when various finishes are applied; these cases represent typical 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; Normal fluctuations between different labs will only compound the inaccuracy of test results.

  21. Conclusions (con’t) Expectation: The increase in HR caused by a particular paint or decorative should be independent of the identity of the surrogate panel. Result: HR increase not independent of surrogate identity Based on the above, it would be very difficult to adopt a standardized procedure in which renovated interiors could be certified using surrogate materials.

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

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

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