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QUALIFICATION TEST FOR A/C PANEL ADHESIVES

QUALIFICATION TEST FOR A/C PANEL ADHESIVES. Establish similarity of bonded details. OBJECTIVE. Develop a qualification test for flammability of adhesives used in bonded details. PURPOSE. APPLICATIONS. Certification of New Parts. ADHESIVES TASK GROUP.

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QUALIFICATION TEST FOR A/C PANEL ADHESIVES

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  1. QUALIFICATION TEST FOR A/C PANEL ADHESIVES

  2. Establish similarity of bonded details. OBJECTIVE Develop a qualification test for flammability of adhesives used in bonded details. PURPOSE APPLICATIONS Certification of New Parts

  3. ADHESIVES TASK GROUP 3MAmerican AirlinesBoeingBombardierBostikC&D AerospaceDassaultFAAHenkel

  4. INDUSTRY-PROPOSED METHODS OF COMPLIANCE FOR CERTIFICATION OF INTERIOR MATERIALS Part 2: Methods That Will Require Supporting Data 25.853(a) Bunsen Burner Similarity 25.853(d) Heat and Smoke Similarity Ref. No. Feature / Construction Test required if: A > 2 ft2 Possible Test if: 1 < A < 2 ft2 No test required* if: A < 1 ft2 Testing detail without adhesive* to Appendix F substantiates the bonded configuration BONDED DETAILS 28 *For FAA Qualified Adhesives?

  5. ADHESIVE QUALIFICATION TEST ISSUES FAR 25 versus Other Measurement MethodSample FormEffect of AdherendsEffect of Thickness: Does thinner substantiate thicker?

  6. 70 70 60 60 50 50 40 40 30 30 20 20 10 10 0 0 -10 -10 Example: Thermoplastic Thickness Ranges Peak HRR Proposed range Peak Heat Release Rate, kW/m2 Total Heat Release, kW-min/m2 Total Heat Release EUROPLEX PPSU Clear 0 .040 .080 0.12 0.16 0.20 0.24 0.28 Thickness, inches OSU Peak HRR of 0.040doesnot substantiate .080- 0.16

  7. Standard Test Method for Measuring Flammability Properties of Plastics and Other Solid Materials Using Microscale Combustion Calorimetry, ASTM D 7309 Oxygen Inlet Scrubber Flow Meter Combustor O2 Sensor Mixing Section Exhaust Sample Cup Pyrolyzer Purge Gas Inlet Sample Post & Thermocouple

  8. 500 400 300 200 100 0 THERMAL COMBUSTION PROPERTIES FROM MCC Peak Heat Release Rate = Heat Release Capacity (J/g-K) c hc Total Heat Release (J/g) Heat Release Rate (J/g-K) Tp  Burning Temperature  Noncombustible Fraction (g/g) 250 300 350 400 450 500 550 800 850 Temperature (°C)

  9. HEAT RELEASE CAPACITY VERSUS COST OF PLASTICS Commodity Plastics 1000 PE PP PMMA ABS PS NYLON 66 Epoxy PU PET PAR PPO Engineering Plastics PSU POM PC PES PVF PVC (rigid) PPS Heat Release Capacity (c), J/g-K PEEK Phenolic 100 Heat Resistant Plastics LCP PEI PEK PPSU TYPICALLY PASS FAA HRR TEST PAI KAPTON 10 1 10 100 0.1 Materials Cost* ($/lb) *Truckload Prices, 2001

  10. 1 0.8 0.6 0.4 0.2 0 0 200 400 600 800 1000 1200 VERTICAL BUNSEN BURNER TEST (114 plastics) Probability of Passing the UL 94 V-0 Requirement ASTM D 3801 Probability of Passing VBB, p *= 448 J/g-K n = 4.46 R = 0.97 Heat Release Capacity c, J/g-K

  11. HAND LAY-UP OF ADHESIVE / RESIN OSU SAMPLES • Fiberglass-reinforced adhesive samples are made by hand lay-up. • Samples cured between two Teflon-coated aluminum plates in heated press. • Cured samples trimmed to 6 x 6 for OSU HRR testing. • Resulting samples ~ 40% resin by weight.

  12. OSU TESTING OF ADHESIVE RESINS Peak HRR 2-min HR Resin (kW/m2) (kW-min/m2) BPA Epoxy 111 44 BPAE + MDA 88 26 BPA CE 72 28 BPC Epoxy 48 28 Silicone Resin 33 12 BPC CE 13 13

  13. 200 150 100 50 0 0 100 200 300 400 500 600 700 OSU PHRR (binned data) 101 RESINS AND PLASTICS) Maximum Heat Release Capacity from Curve Fit (R = 0.8264) avg pHRR, kW/m2 c, J/g-K

  14. c y pHRR c p = P/(P + F) OSU Data for AIRCRAFT CABIN MATERIALS 1 9 10 13 15 22 29 50 105 108 115 120 120 121 121 127 129 136 140 141 152 153 155 156 159 173 192 196 201 203 215 215 230 235 248 261 265 276 295 298 301 316 345 349 359 8 25 59 13 66 31 55 30 54 92 61 49 123 60 52 109 64 65 69 110 90 30 85 45 72 106 36 32 74 65 213 150 97 258 55 44 188 199 93 211 232 166 115 207 90 P P P P F P P P P F P P F P P F P P F F F P F P F F P P F P F F F F P P F F F F F F F F F 36 9/10 = 0.90 127 6/10 = 0.60 Transform Quantitative Data into Qualitative Data Using Pass/Fail Criterion 3/10 = 0.30 174 14 CFR 25.853 • HRR  65 kW/m2 = Pass = P • HRR > 65 kW/m2 = Fail = F 254 4/10 = 0.40 0/10 = 0.00 355 Etc.

  15. 1 0.8 0.6 0.4 0.2 0 0 100 200 300 400 500 600 700 OSU PHRR (101 RESINS AND PLASTICS) Probability that pHRR  65 kW/m2 14 CFR 25 Probability of Passing OSU pHRR, p = 102 J/g-K *= 140 J/g-K n = 2.4 R = 0.97 Heat Release Capacity (c), J/g-K

  16. EFFECT OF ADHERENDS and THICKNESS (Additive Approach Using MCC Data) construction = mpp + maa + mss p , p Part a , a Adhesive s , s Substrate i = Areal Density of Layer i, g/m2 i= Heat Release Capacity of Layer in MCC i, J/g-K mi = Mass Fraction of Layer i = i /i

  17. EFFECT OF ADHERENDS and THICKNESS (ThermaKin Numerical Burning Model) Transient energy and mass balance calculation Ti, , hc, E, A, etc. Part Ti, , h, E, A, etc. Adhesive Ti, , h, E, A, etc. Substrate Ti = Thickness of Layer i, cm i = Density of Layer i, g/m3 hi= Heat Release of Layer, J/g Ei , Ai = Thermal Decomposition Kinetic Parameters of i

  18. OSU HRR OF BONDED CONSTRUCTION (ThermaKin Simulation) Heat Flux = 35 kW/m2 (OSU) + 15 kW/m2 (Flame) Substrates = 1/16 (1.5 mm) Thick Charring Plastic (Polycarbonate) Adhesive Layer Thickness = 0.2, 0.5, 1 and 1.5 mm hc = 2X Substrate

  19. 1 1 1 1 0.8 0.8 0.8 0.8 0.6 0.6 0.6 0.6 0.4 0.4 0.4 0.4 0.2 0.2 0.2 0.2 0 0 0 0 0 1 2 3 4 5 0 1 2 3 4 5 1 1 1 1 0.8 0.8 0.8 0.8 0.6 0.6 0.6 0.6 0.4 0.4 0.4 0.4 0.2 0.2 0.2 0.2 0 0 0 0 0 1 2 3 4 5 0 1 2 3 4 5 OSU HRRs of BONDED CONSTRUCTIONS (ThermaKin) 0.2 mm Adhesive Layer 0.5 mm Adhesive Layer HRR (arbitrary units) HR (arbitrary units) Time, min Time, min 1.5 mm Adhesive Layer 1 mm Adhesive Layer Time, min Time, min

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