# Presentation: 512613

## Tim Marker

- Laboratory & Full Scale Testing of
- Non Traditional Lightweight Aircraft Seats

- FAA Technical Center

## Problem: Next Generation aircraft seats utilizing lighter materials in their

- construction are unfairly restricted by the FAR-mandated 10% weight loss criteria.

- Example: 5 lb seat

- [(5.0-4.6) / 5.0] x 100 = 8.0%  PASS

- % Weight Loss = (initial weight – final weight) / (initial weight) x 100

- 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.

## 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)

- “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.”

- Bottom: 18 W x 20 D x 4 T

- Back: 18 W x 25 H x 2 T

## Testing Proposed by FAATC in June 2002 

- lab-scale tests (oil burner)

- Proceed with full-scale evaluation using remaining 12 sets

- Confirm seats exceed 10% weight loss

- Testing Proposed by FAATC in June 2002

*If Yes*

## Description of Materials

- Baseline Seat 1 (6 tests)

- Standard fire retardant foam, 2.75 lb/ft3 density

- Standard 90/10 wool/nylon blend dress cover

- Baseline Seat 2 (3 tests)

- Standard fire retardant foam, 2.75 lb/ft3 density

- Standard 90/10 wool/nylon blend dress cover

- PBI felt fire blocking fabric, 290 g/m2

- PBI felt fire blocking fabric, 290 g/m2

## Description of Materials (con’t)

- Lightweight Seat A (6 tests)

- Fire hardened foam, 0.62 lb/ft3 density, no blocking layer

- Lightweight Seat B (6 tests)

- Lightweight Seat C (6 tests)

- Lightweight Seat D (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 foam 0.59 lb/ft3, no blocking layer

- Dress Cover: Wool 91% / PA 9% 380 g/m2

- Fire hardened foam, 2.2 lb/ft3 density, no blocking layer

- Dress Cover: Wool 91% / PA 9%, 375 g/m2

- Dress Cover: Wool 90% / PA 10%, 380 g/m2

## 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

## Full-Scale Test Parameters

*Interior Materials*

- 0.25-Inch thick crushed-core Nomex honeycomb panels, meets 65/65

- Aircraft-grade carpet, meets VBB

*Test Execution*

*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

- 55 gallon JP8 fuel fire in 8’ by 10’ pan adjacent to fuselage

- External fuel fire extinguished following noticeable flashover

## Full-Scale Test Parameters

- 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 @ 5:30

- CO2 Extinguishing Agent applied to interior @ 6:30

## Full-Scale Test Parameters

- Weight Loss ranged from 15 to 25% in Lab Test

- Lightweight Seat A

- 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 @ 5:30

- CO2 Extinguishing Agent applied to interior @ 6:30

- AFFF applied to pan fire @ 4:30

- CO2 Extinguishing Agent applied to interior @ 5:30

## Full-Scale Test Parameters

- Weight Loss ranged from 10 to 17% in Lab Test

- Lightweight Seat C

- 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 @ 5:30

- CO2 Extinguishing Agent applied to interior @ 6:00

- AFFF applied to pan fire @ 5:15

- CO2 Extinguishing Agent applied to interior @ 5:30

## Full-Scale Test Apparatus

## Seat Identification & Thermocouple Location

## Full-Scale Test Configuration in 707

## Full-Scale Test Configuration in 707

## Full-Scale Test Configuration in 707

## View Into Fire Door in 707

## Thermocouple Placement on Seats

## Close-up of Seat Thermocouple

## Typical Cabin Fire @ 1:00

## Typical Cabin Fire @ 2:00

## Typical Cabin Fire @ 3:00

## Typical Post Event

## 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.

## 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 5:00 minutes.

- Lightweight seats A, C, and D resulted in a more subtle flashover condition, occurring slightly later, approximately 5:00 to 5:30 minutes.

- Lightweight B resulted in a quicker flashover condition, approximately 3:30 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.

## $$$$ What is Lightweight? $$$

## Possible Acceptance Criteria

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