Tim Marker

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Laboratory Full Scale Testing of Non
Traditional Lightweight Aircraft Seats
Tim Marker
FAA Technical Center
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Problem Next Generation aircraft seats utilizing
lighter materials in their construction are
unfairly restricted by the FAR-mandated 10
weight loss criteria.
Weight Loss (initial weight final weight) /
(initial weight) x 100
Example 5 lb seat
(5.0-4.6) / 5.0 x 100 8.0 PASS
Example 3 lb seat
(3.0-2.6) / 3.0 x 100 13.3 FAIL
Proposed Testing Evaluate performance of
lightweight seat cushions under realistic
conditions.
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Testing Proposed by FAATC in June 2002
Supply 18 Sets of Test Cushions to FAATC
Test Cushion Construction per FAR 25.853(c)
Appendix F, Part II (or Handbook)
Back 18 W x 25 H x 2 T
Bottom 18 W x 20 D x 4 T
Each specimen tested must be fabricated using
the principal components (i.e., foam
core, flotation material, fire blocking material,
if used, and dress covering) and
assembly processes (representative seams and
closures) intended for use in the production
articles. If a different material combination is
used for the back cushion than the bottom
cushion, both material combinations must be
tested as complete specimen sets, each set
consisting of a back cushion specimen and a
bottom cushion specimen.
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Testing Proposed by FAATC in June 2002

• FAATC randomly selects 6 sets of cushions to
  conduct
• lab-scale tests (oil burner)

• Confirm seats exceed 10 weight loss

If Yes

• Proceed with full-scale evaluation using
  remaining 12 sets

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Description of Materials
Baseline Seat 1 (6 tests)
Standard fire retardant foam, 2.75 lb/ft3 density
PBI felt fire blocking fabric, 290 g/m2
Standard 90/10 wool/nylon blend dress cover
Baseline Seat 2 (3 tests)
Standard fire retardant foam, 2.75 lb/ft3 density
PBI felt fire blocking fabric, 290 g/m2
Standard 90/10 wool/nylon blend dress cover
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Description of Materials (cont)
Lightweight Seat A (6 tests)
Fire hardened foam, 0.62 lb/ft3 density, no
blocking layer
Dress Cover Wool 91 / PA 9, 375 g/m2
Lightweight Seat B (6 tests)
Fire hardened foam, 2.2 lb/ft3 density, no
blocking layer
Dress Cover Wool 90 / PA 10, 380 g/m2
Lightweight Seat C (6 tests)
Fire hardened foam 3.0 lb/ft3 lightweight foam
0.59 lb/ft3, no blocking layer
Dress Cover Wool 91 / PA 9 380 g/m2
Lightweight Seat D (6 tests)
Lightweight foam 0.59 lb/ft3, no blocking layer
Dress Cover Wool 91 / PA 9 380 g/m2
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Lab-Scale Test Results
PASS
PASS
FAIL
FAIL
FAIL
FAIL
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Analysis of Laboratory Tests on Lightweight Seats

• Bottom dress cover yields higher weight loss
  than bottom cushion in all cases

• Back dress cover yields higher weight loss than
  back cushion in A, C, and D

• Ratio of total cushion weight to total dress
  cover weight ranged from .65 to 2.2

Lightweight Seat A ratio 0.65
Lightweight Seat B ratio 1.99
Lightweight Seat C ratio 2.19
Lightweight Seat D ratio 1.60
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Full-Scale Test Parameters
Test Article
B707 fuselage, fully fire hardened interior
Instrumentation
Continuous gas analysis at 2 locations, 2 heights
Temperature measurement 3 thermocouple trees
individual seat thermocouples
Smoke measurement smoke-meters at 2 locations, 3
heights each
4 interior video cameras, 2 external
Interior Materials
0.25-Inch thick crushed-core Nomex honeycomb
panels, meets 65/65
Aircraft-grade carpet, meets VBB
Test Execution
55 gallon JP8 fuel fire in 8 by 10 pan adjacent
to fuselage
External fuel fire extinguished following
noticeable flashover
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Full-Scale Test Parameters
Baseline Test
Fire Blocked Urethane Using PBI Felt Material
with 90/10 Wool/Nylon Dress
Weight Loss ranged from 6 to 10 in Lab Test
AFFF applied to pan fire _at_ 530
CO2 Extinguishing Agent applied to interior _at_ 630
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Full-Scale Test Parameters
Lightweight Seat A
Fire hardened foam, no blocking layer, with 91/9
Wool/Nylon dress cover
Weight Loss ranged from 15 to 25 in Lab Test
AFFF applied to pan fire _at_ 530
CO2 Extinguishing Agent applied to interior _at_ 630
Lightweight Seat B
Fire hardened foam, no blocking layer, with 90/10
Wool/Nylon dress cover
Weight Loss ranged from 11 to 14 in Lab Test
AFFF applied to pan fire _at_ 430
CO2 Extinguishing Agent applied to interior _at_ 530
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Full-Scale Test Parameters
Lightweight Seat C
Fire hardened foam, no blocking layer, with 91/9
Wool/Nylon dress cover
Weight Loss ranged from 10 to 17 in Lab Test
AFFF applied to pan fire _at_ 530
CO2 Extinguishing Agent applied to interior _at_ 600
Lightweight Seat D
Fire hardened foam, no blocking layer, with 90/10
Wool/Nylon dress cover
Weight Loss ranged from 13 to 14 in Lab Test
AFFF applied to pan fire _at_ 515
CO2 Extinguishing Agent applied to interior _at_ 530
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Full-Scale Test Apparatus
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Seat Identification Thermocouple Location
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Full-Scale Test Configuration in 707
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Full-Scale Test Configuration in 707
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Full-Scale Test Configuration in 707
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View Into Fire Door in 707
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Thermocouple Placement on Seats
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Close-up of Seat Thermocouple
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Typical Cabin Fire _at_ 100
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Typical Cabin Fire _at_ 200
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Typical Cabin Fire _at_ 300
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Typical Post Event
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Full-Scale Weight Loss Results
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Analysis of Full-Scale Weight Loss Data

• All tests resulted in high percentage weight loss
  of seats near fire door

• Percentage weight loss of seat 4 a good indicator
  of fire crossing aisle

• Percentage weight loss during full-scale tests
  largely dependent on length
• of test/suppression of the external fire, and not
  a good indicator of overall
• cushion performance.

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Temperature, Fire Gas, and Smoke Levels
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Full-Scale Test Analysis

• Baseline test using traditional fire-blocked
  seats resulted in a flashover condition
• at approximately 500 minutes.

• Lightweight seats A, C, and D resulted in a more
  subtle flashover condition, occurring slightly
  later, approximately 500 to 530 minutes.

• Lightweight B resulted in a quicker flashover
  condition, approximately 330 from start.

• Lightweight C produced more smoke and higher gas
  levels than all others.

• Lightweight D resulted in lowest temperatures,
  smoke, heat flux, and gas levels.

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What is Lightweight?
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Possible Acceptance Criteria
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