FAA Fire Safety - A Case Study: Evaluation of Flame ...FR-COATED INSULATION BLANKETS: POST-FIRE 3...
Transcript of FAA Fire Safety - A Case Study: Evaluation of Flame ...FR-COATED INSULATION BLANKETS: POST-FIRE 3...
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A Case Study: Evaluation of Flame Retardant Coatings for Aerospace Applications
John HarrisMaterial and Process Technology
Boeing Commercial Airplanes
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• Flammability• Cost• Aesthetics
• Mechanical• Weight• Processing
Materials being developed for aerospace applications must meet a large set of engineering requirements:
MATERIALS DEVELOPMENT IN AEROSPACE
Some requirements often work against others.
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What’s the problem ?Defining the best set of engineering
requirementsCommercially available materialsOptimal methods of characterization• Flammability / environmental / physical durability
Development schedule/Cost
OPTIMIZING MATERIALS FOR AEROSPACE APPLICATIONS
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Problem: In-Service Investigations• Flammability, contamination, aging
Flammability testing• Q-tip, Bunsen burner, radiant panel
Highly variable test results• Burn length/self-extinguishing time
Flammability properties impacted by aging and/or contamination ?
CASE STUDY: IN-SERVICE INSULATION BLANKETS
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SOLUTION STRATEGY
Spray-on flame retardant (FR) coating• Compatible with customer process
o Ease of useo Equipment compatible
• Suitable for complex surface• Low material cost• Weight neutral with remove & replace
Reconstitute material flame retardant properties
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PHASE I: EVALUATE COMMERCIAL FLAME RETARDANT COATINGS
Engineering Requirements for coating:Good adhesionFlammability requirements
Low smoke & toxic gas emissionRadiant panel test
Physically durable and flexibleConsistent mechanical / flammability properties with aging
Water resistant and non-absorbent over time
Non-conductive and non-corrosive
Minimal weight impact
Relative ease of application and cure
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INTUMESCENT COATINGS Constituents
Acid source, blowing agent, and carbon source
AdvantagesWeight and volume savingsCompetitive costsGood insulation against static heat sourceCommercially availableHazmat/Toxicity
DisadvantagesNon-durable intumescent foamNon-uniform coating thicknessEquipment/process requirements
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KEY TEST REQUIREMENT: RADIANT PANEL
≤ 3 sec After Burn
≤ 3 in Burn length
Video Deleted
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Commercial FR coating applied to in-service insulation blanket
CONSISTENT RADIANT PANEL RESULTS OBTAINED
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PHASE I SUMMARYProperty Requirements met:
Radiant panel & smoke emission requirementsWater soluble & non-toxicHVLP spray applicationNon-conductive & non-corrosiveMinimal weight impact
Property Requirements NOT met:Water resistant only after long cure (> 1 month)Loses some flexibility with agingElevated temperature cure
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PHASE II: USE 3 PART COATING SYSTEM TO COMPLETE PROPERTY REQUIREMENTS
Adhesion promoter• Latex-based, flame retarded adhesive
Active coating• Spray-on Intumescent
Barrier coating• Provides resistance to moisture and durability
Coverage/configuration control addressed by coloration
Barrier coating (solvent-based)Active coating (water-based)Adhesion promoter (water-based)
All 3 componentsapplied separatelywith HVLPspray gun or brush
Insulation blanket cover film
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After Burn 12 seconds Burn Length 11.6 inches
Barrier Coating EvaluationsTough meeting both water resistance and radiant panel
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ENCOURAGING RESULTS WITH ACRYLIC BARRIER
Quick drying, completely water resistant, & flexibleConsistent Q-tip and flaming block test results
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FR-COATED INSULATION BLANKETS: POST-FIRE
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3 PART FR COATING CRITICAL ISSUES Active coating: Elevated Temperature Cure is costly
New version FX-100 cures at room temperatureBarrier coating: Inconsistent radiant panel test results
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PHASE II SUMMARY
Acceptable coating propertiesWater resistanceDurabilityNon-conductive / non-corrosiveCost / weightSmoke density & toxicity
Unacceptable coating propertiesInconsistent radiant panel test resultsElevated temperature cureMultiple spray processes
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PHASE III TWO-PART FR COATING SYSTEM
Consistent customer pull for key coating properties• Easy / flexible application method• Short cure times / no elevated temperature cure• Haz Mat concerns: Low toxicity
Key Engineering requirements• Radiant panel, smoke density & toxicity requirements• Durable / flexible / low aging impact• Water resistant
Barrier coating: water or solvent basedActive coating: water-based
HVLPor Brush Application
Insulation blanket cover film
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Radiant Panel Testing Results: 2-Coat SystemSpray-on coating system: inconsistent radiant panel results
Video Deleted
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BARRIER COATING ISSUES
Water-Based formulations• Low toxicity• Meets radiant panel requirements• Questionable water resistance
Solvent-based formulations• Good water resistance• Flexible• Inconsistent radiant panel results
o Entrapped volatiles ?
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REFORMULATED BARRIER COATING Consistent Radiant Panel Results
Video Deleted
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COATING FLEXIBILITY EVALUATION
Twist / Flex Test Method
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10,000 cycles / 180o Testing Control
Both insulation blankets coated at the same time with 2 coat system
COATING FLEXIBILITY EVALUATION
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ACCELERATED AGING: 26,000 FREEZE-HEAT CYCLES
Sprayed daily with water
-50 F – 150 F
Thermal cycling study of FR coating (2 part)
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AGED COATINGS EXHIBITS CRACKING
26,500 heat-Freeze cycles
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Engineering requirements met:Ease of application, cure temp/timeNon-conductive, non-corrosive, water resistanceSmoke density & toxicity, radiant panelLow weight, cost
Engineering requirements NOT met:Cracking / chipping still an issue
• Twist and flex• Environmental aging
TWO PART FR COATING SUMMARY
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FUTURE DEVELOPMENTAL WORK
New formulations: • Barrier• Active
Further research with suppliersSingle application coating
development