FAA Composite Plan and Administration Federal Aviation ......3. Tools that use the data from 1...

Federal AviationAdministrationFAA Composite Plan and

Associated Research Topics

Presented to AMTASBy Cindy Ashforth, FAANovember 6, 2019

Federal AviationAdministration

• In use since FY14• A short (<10 page) document that summarizes potential safety risks and

opportunities for standardization associated with the use of composites in aviation products– Aviation Safety (AVS)-level plan (implemented by flight standards, aircraft certification

and manufacturing inspection offices)– (up to) 7-year plan, updated annually– Safety management principles used to select subjects and prioritize deliverables

• Defines mitigating actions for the FAA - rulemaking, policy, guidance, and training materials - as well as actions for industry (new FY2020)– Identifies prerequisite industry and research activities

• Divided into subjects under Continued Operational Safety, Certification Efficiency and Workforce Education

FAA Composite Plan

November 5, 2019 FAA Research Overview 2


FY19 FAA Composite Plan Proposed List of Initiatives (as of 5/2019)

Continuous Operational Safety (COS)

Certification Efficiency (CE) Workforce Education (WE)

COS A: Bonded Structure CE A: Fatigue & Damage Tolerance Substantiation WE A: Workforce Training

COS B: Closed CE B: Closed WE B: Industry Training and International Outreach

COS C: Failure Analysis of Composites Subjected to Fire

CE C: Composite Structural Modifications

CE D: Composite Quality Assurance

CE E: Bonded Structure Guidance

CE F: General Composite Structure Guidance

CE G: Engine Applications Guidance

CE H: Composite TSO

Changes from last approved version in

red

Document that summarizes potential safety risks and opportunities for standardization (Initiatives) associated with the use of composites in aviation products

Defines mitigating actions (Deliverables) for the FAA - rulemaking, policy, guidance, and training materials – and industry



• Two COS items in the Composite Plan:A. Bonded Structure

• Bonded repairs• Bond quality control• Sandwich disbond growth

B. Closed • Was HEWABI (high energy wide area blunt impact), which is closed after release

of a transport policy and internal webinar. Follow-on tasks for research and industry documentation are moved to initiative CE A for fatigue and damage tolerance.

C. Failure analysis of composites subject to fire

Continued Operational Safety (COS) Initiatives



COS ItemsCOS A: Bonding

COS C: Failure Analysis of Composites Subjected to Fire

Bonding safety risks include bonded repairs, bondline durability* and sandwich disbond growth*additional new rotorcraft emphasis

Support CMH-17 to publish Volumes 1 and 3 Rev H with new content on bonding, Fall 2021 (includes research funds)Develop a Short Course for Bonded Repair Design, Substantiation, and Approval based on CMH-17, Fall 2022Create new AC or update AC 20-107B with additional bonding content, Draft Spring 2023

Support CMH-17 to publish Volume 6 Rev B with new content on sandwich structure, Spring 2023 (includes research funds)Create new AC or update AC 20-107B with additional sandwich content, Draft Spring 2024

Can we determine if there was a structural failure after an accident and post-impact fire?

Fund research FY19-FY22

Publish update to Composite Failure Analysis Handbook (joint publication between the FAA and Air Force, last updated 1995) FY2023

Being asked: Why duplicate work? Why can’t a standards group directly publish MOC content?



Research that Supports COS Initiatives


• Moisture Diffusion in Sandwich Composites

• Effect of Surface Contamination on Composite Bond Integrity and Durability Project

• Durability of Adhesively Bonded Joints for Aircraft Structures Project

• Durability of Bonded Aerospace Structures• Improving Adhesive Bonding of Composites Through Surface

Characterization

• Nanomechanical Characterization of Adhesive Bondlines


• Certification Efficiency (CE) initiatives capture best industry practices via regulatory guidance and industry standards documents.

– Goal is to standardize methods to certify composite structures and repairs which will address the current industry practice of using proprietary databases and advanced procedures.

• Seven CE initiativesA. Fatigue and Damage Tolerance SubstantiationB. Closed

• Was Advanced Composites Maintenance – the two deliverables are no longer supported by AFS

C. Composite Structural ModificationD. Composite Quality ControlE. Bonded Structure GuidanceF. General Composite Structures GuidanceG. Engine Installation GuidanceH. Material TSO

• Additional standardization activities in the area of transport crashworthiness, fuel tank lightning protection, and composite flammability These FAA initiatives have some components specific to composites, but are not managed as part of the

composite plan

Certification Efficiency Initiatives



Certification Efficiency ItemsCE A: Fatigue and Damage Tolerance

CE C: Composite Modifications

F&DT engineering protocols for composite aircraft structures differ significantly from metal engineering practices; hybrid structures anadditional complexity

Policy on interpreting existing 25.571 amdt for composite structure, TBD (AIR-675 deliverable)

Support 25.571 ARAC Report, due 12/2019

Revised 25.571 and associated guidance (may include AC 20-107B update), Draft 12/2020

Ongoing research to supplement documentation in CMH-17, FY19-FY23

New applicants modifying critical composite structures, such as with installation of antennas on 787 or A350 aircraft. Safety risk with new applicants do not have experience in modifying critical composite structure, and FAA offices have requested guidance

Identify standards organization to publish portions of the content, 12/2019

Support standards organization to publish portion of the content already written for the AC, Date TBDPublish new AC on composite modifications that will summarize key points from industry publication highlighting what to worry about and why, Date TBD to correlate with industry document

Can/Should all information go in an industry publication?



Certification Efficiency ItemsCE D: Composite Quality Assurance

CE E: Structural Bonding– Same as COS A, but from a certification best practices / cert efficiency perspective

CE F: General Composite Guidance

Recent composite manufacturing techniques may not be able to utilize traditional quality control methods, Current QC ACs have type design information and 2x.605 MOC

Research report on latest manufacturing techniques and associated key characteristics and key process parameters, Draft summer 2019Create an appendix in AC 21-43 with unique considerations for composite quality system oversight and cancel ACs 21-26 and 21-31, Draft winter 2020Identify gaps in M&P guidance from canceling QC ACs and if so, develop plan to supplement advanced M&P policy, AC 20-107 and/or industry standards (most likely CMH-17), Spring 2020

With evolving/advancing composite technology and expanding composite applications, AC 20-107 “Composite Aircraft Structure” requires revision

Revise AC 20-107, “Composite Aircraft Structure,” to incorporate advanced composite technologies and lessons learned, draft Spring 2024 (timed to coincide with sandwich structure update under COS A / CE E)

• Will follow CMH-17 Volume 3 Rev H and Volume 6 Rev B• Will include latest lessons learned from research



Certification Efficiency ItemsCE G: Engine Guidance

Engine cert projects with composites have been managed on a case-by-case basis by adapting AC 20-107B for composite aircraft structure. Unique concerns with engines warrant individualized guidance

Held CSTA workshop on engine applications and identify scope of engine AC, September 2019Write a new AC for composite engine applications, that refers to AC 20-107B, but puts in context of engine applicationsEngage engine industry with CMH-17 CMC and PMC coordination groups by holding joint meeting summer 2020



Research that Supports CE Initiatives


Failure of Notched Laminates Under Out-of-Plane Bending CE AEvaluation of Parameters Used in Progressive Damage Models CE ADevelopment and Evaluation of Fracture Mechanics Test Methods for Sandwich Composites - Damage Tolerance Test Method Development CE A

Moisture Diffusion in Sandwich Composites CE ADevelopment of a Building Block Approach for Crashworthiness Testing N/AEffect of Surface Contamination on Composite Bond Integrity and Durability Project CE E

Durability of Adhesively Bonded Joints for Aircraft Structures Project CE EDurability of Bonded Aerospace Structures CE EImproving Adhesive Bonding of Composites Through Surface Characterization CE ENanomechanical Characterization of Adhesive Bondlines CE ECertification of Discontinuous Fiber Composite Material Forms for Aircraft Structure CE F, CE D


Certification Efficiency ItemsCE H: Composite TSONew initiative for development of basic material data plus optional advanced material data and/or design tools. Allows companies to demonstrate technology readiness outside of a certification project.

Hold workshop to gauge industry interest and identify a standards organization(s) to work with, Winter 2019

Identify if any standards organization documentation is required, and scope working agreement(s), Spring 2020

Draft Minimum Performance Standard, TSO, and associated guidance, Winter 2021


New proposed initiative

since 9/2018


• Under the current system, we do not open certification projects for development of composite data

• Some DAHs open projects to develop allowables and associated tools, then cancel the project – Data, however, is FAA approved and can be applied to other projects, when shown to

be applicable• Other parties have no avenue to develop data that is approved by the

FAA– Some basic material data may be generated under NCAMP system accepted by the

FAA, but that ties applicants to one testing house– No higher-level data can be developed and accepted by the FAA (i.e., no conformity or

witnessing without a project number)

Why do we need a TSO?



• Parties could develop data that would be approved by the FAA without a certification project– The data would be restricted to a well-documented design space– Certification activities are still required in order to use the material and data – it has to

be shown to be applicable to the project; however, the tests used to develop the data would not have to be re-performed with project numbers, conformity, and witnessing (this is managed under the TSOA quality system)

– Brings parity to third parties so they can develop data in an economical method, the same as current DAHs

• There would be a significant advantage to the FAA to receive data packages with the TSO application that describe the limitations of the data – a learning tool and design guide

New TSO System



• We are considering developing a new TSO and associated guidance for composite materials– Guidance is essential in order to implement the TSO, since it is a new

concept• Addresses multiple segments of the industry:

– Material suppliers– Companies who want to develop data that they can get credit for,

independent of an FAA certification project• Includes development of basic material data plus optional

advanced material data and/or analytical tools

What is it?



• There could be three classes of data1. Basic lamina-level M&P control data

• NCAMP-style data• Requires a single material and process specification• Could be developed by a material manufacturer (e.g., prepregger) or an end-user (perhaps

to develop data for a different cure process)• TSO would reference existing published test standards and statistical methods to generate

this data2. Advanced laminate or detailed design data

• Class 1 data is a prerequisite• Likely developed by an end-user (such as a partner responsible for design or supplier to

propose an alternative design) for unique design details (e.g., structural joints, effects of defects and strength after impact) above the base lamina level used for material control

• TSO would not prescribe test methods (i.e., no existing industry standards)

Candidate TSO Content



• There could be three classes of data (cont.)3. Tools that use the data from 1 and/or 2

• Class 1 or 2 is a prerequisite – design and analysis tools must be tied to material control and test data developed under TSO

• Allows development of analytical tools (e.g., closed-form solutions or FEM) to use the properties developed in 1 or 2

• Must include documentation of HOW to use the data and LIMITATIONS for the data– Limitations are in addition to the M&P restrictions and could include design details (radii, thickness),

loading limitations (e.g., stringer spacing, joint details) or other design constraints (e.g., requirements, limits, criteria)

• Essentially creating a stand-alone design guide for a given material system, manufacturing process, and design and installation details

Candidate TSO Content



Workforce Education Initiatives

• An essential component for COS and CE is a comprehensive educational development program

• Successful composite safety and certification oversight is dependent upon our workforce being knowledgeable of both basic and advanced composite technologies and terminologies– Includes International Standardization and Outreach

• Reorganized into two activities – internal FAA training and external outreach/training– Continuing to update/maintain training classes for AFS, ACO and MIDO workforces– All outreach activities, including workshops, documented under this initiative



Workforce Education Initiatives

Incl. three levels of competency:– Introduction (“Composites 101”)– Safety Awareness (courses for each functional discipline)

• Skills needed for FAA workforce supporting composite applications– Specific Skills Building (most courses developed by the industry)

• Specialized skills needed in the industry and some FAA experts

FAA Sponsor

FAA Facilitator

Industry Support

Industry Sponsor

Degree of Involvement

And Investment

Educ

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evel

opm

ent

Educ

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n D

evel

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ent

Introduction

Safety Awareness

Specialized Training

FAA composite training supports three segments of our workforce: engineering, manufacturing and maintenance Compliments training available in industry

and academia



Workforce Education ItemsWE A: Bonding

WE B: Industry Training and International Outreach

The FAA has developedcomposite training for ACO engineers, MIDO inspectors and FSDO inspectors. All classes require periodic updates.

Updated CMfgT course offered through WSU with revised content, lesson plans and a job aid, Fall 2020 (coordinate with revised AC 21-43 under initiative CE C)Updated CSET course offered through WSU with revised content, lesson plans and a job aid, 12/2019Coordinate with AFS to submit request to update CMT course offered through Abaris,Fall 2019

Industry workforce development is an important educational initiative, separate from internal education

Jointly host an educational workshop with an industry partner, winter or spring2020Deliver certification tutorial and composite training at multiple venues, FY19-20



Questions



• Under Structural Integrity of Composites research group, we create research requirements by top-level subject – Think of as “buckets” projects fit within

• For FY2020, the subjects are:– SIC.1: Damage Tolerance of Composite Structures– SIC.2: Composite Maintenance Practices– SIC.12: Continued Operational Safety (COS) and Certification Efficiency (CE) for

Emerging Composite Technologies– SIC.14 Certification and Maintenance Protocols for Bonded Joints

Reminder - Composite Research Topics



• Be thinking about:– What kind of projects you would like to do? – What “bucket” would it would fit in, or do we need a new one?– Will it support the composite plan?– What role will the research play?

1. Evaluate new tools and techniques proposed by applicants2. Provide publically available data where none exists that supports continued

operational safety (support publishing lessons learned)3. Answer specific questions related to service events4. Develop tools to promote standardization and increase certification efficiency

For Discussion


FAA Composite Plan and Administration Federal Aviation ......3. Tools that use the data from 1...

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