# Presentation: 289688

## OSU & NBSMarch Materials Meeting

- Materials Working Group

- Michael Burns, FAA Tech Center

- June 17th & 18th, 2008

## Agenda

- Present results of mini round robin
- Any progress to inspection of equipment?
- NBS furnace update
- Photometric System Round Robin
- Next steps

**Notes:**
Materials, including finishes or decorative surfaces applied to materials, must comply with CFR 25.853 including it’s appendix F.  This FAR addresses the  flammability requirements in compartments occupied by crew or passengers in commercial aircraft.
In this presentation the test of interest is the OSU Heat Release Rate and the NBS Smoke Chamber testing
For the past ten years or so the Boeing company has been the principal Investigator of the annual round robin tests that were conducted.
Thee FAA has assumed this role for the 2006/2007 series of tests.
The Round Robin is a tool we employ to identify laboratories that may not be operating their fire tests in compliance with applicable FAA requirements.
The basic premise of how a “ROUND ROBIN”  test method  works is 
- the Principal Investigator mails out the same samples to each lab
 Participating labs conduct the smoke chamber test and then return the sample data for analysis.  
Theoretically, all samples should produce the same results.
THE PROBLEM IS....

## 2007 Independent Mini-Study 

**The follow-on ‘Mini-Study’ has been completed**
**Review included an on site visit as well as the testing of two honeycomb panels identified as 7800 and S-SCCP for the OSU and 7700, 7800 for the NBS**
**Data presented are tests made prior to repairing any discrepancies that were found during visit**
- One Lab was able to complete repairs and run panel S-SCCP (OSU) a second time
**OSU data is presented as Peak Heat Release Rate, 2 minute Total Heat Release Rate, Time to Peak and a one standard deviation bracket**
**NBS data is presented as maximum optical density observed during the four minute test and a one standard deviation bracket**

**Notes:**
A Follow-on ‘Mini-Study’ is being conducted to help investigate why results were so variable

This mini round robin recently exposed some problems that may be more wide spread than anticipated.

This study included one international and 6 domestic laboratories

One of the domestic labs are new and requested to be part of this series of tests

A comprehensive site visits was completed identifying process errors and apparatus deficiencies.

Once these discrepancies are addressed sample testing can be completed

The intent of this review is to  improve and ensure validity and reliability of future results

## Slide 4

**Notes:**
Many  problems were found during the visits to  the labs in the mini-study

A ‘Cold inspection’ of dimensions on the NBS Smoke chamber and OSU were conducted and resulted in numerous issues that I will highlight in the coming slides

A ‘Hot inspection’  of operational procedures also revealed some problems

And I will discuss two other issues such as furnace defects and equipment altering that may have also been contributing factors.

## Slide 5

**Notes:**
Over the next few minutes, I would like to review the most recent international round robin

As follow-on work to this round robin a mini study was organized to look a just a few random labs more closely to try to find any problems that may be present in the field to help explain these errors

I will then present conclusions and recommendations as well as a forecast for future plans

## Slide 6

**Notes:**
Over the next few minutes, I would like to review the most recent international round robin

As follow-on work to this round robin a mini study was organized to look a just a few random labs more closely to try to find any problems that may be present in the field to help explain these errors

I will then present conclusions and recommendations as well as a forecast for future plans

## Slide 7

**Notes:**
Over the next few minutes, I would like to review the most recent international round robin

As follow-on work to this round robin a mini study was organized to look a just a few random labs more closely to try to find any problems that may be present in the field to help explain these errors

I will then present conclusions and recommendations as well as a forecast for future plans

## Slide 8

**Notes:**
27 labs participated in all
- North America: US and Canada
- Europe:  Germany, Italy, Spain, France, Austria, Switzerland, United Kingdom
- Asia:  China and Japan

To be in compliance labs can conform to either the FAA Rule or the FAA Handbook however not a combination of the two.  The FAA Handbook was written from the rule, however is considered more of an operators manual that is continually updated by way of supplements.

There were a total of 243 samples involved made up of 3 samples of 3 different materials identified as sample 5300, 5400 & 5500.

## Slide 9

**Notes:**
The Good news...
All 27 labs completed the test and reported data
The Bad news...
Data is unfortunately inconsistent

Suspect test equipment and/or procedures may have been compromised. 

The full report can be found on the FAA fire safety web site

## NBS Test Results

## Slide 11

**Notes:**
The Good news...
All 27 labs completed the test and reported data
The Bad news...
Data is unfortunately inconsistent

Suspect test equipment and/or procedures may have been compromised. 

The full report can be found on the FAA fire safety web site

## Slide 12

**Notes:**
The Good news...
All 27 labs completed the test and reported data
The Bad news...
Data is unfortunately inconsistent

Suspect test equipment and/or procedures may have been compromised. 

The full report can be found on the FAA fire safety web site

## Following Mini Study, FAA Requested All Participating Labs to:

**Review mini-study findings posted on the FAA Fire Safety web site**
- Do you have similar problems (OSU & NBS)?
**Conduct thorough internal review of equipment and procedures**
**Review must address the following issues:**
- List discrepancies found during inspection
- Course of action
- Estimated completion date for all necessary repairs
**Notify FAA once review is complete**

**Notes:**
Request all participating laboratories...
Review mini-study findings (do you have similar problems?)
Conduct thorough internal review of equipment and procedures before next Round Robin is scheduled
Notify FAA once review is complete and submit findings no later than 6/1/2008

## NBS Furnace

**FAA has been informed that any manufacturing defect previously noted has been corrected and that there is no longer a dark eye observed in the center of the furnace**
**Updated furnace drawing specifications are nearly complete and will be in the next update of Chapter 6.**
**FAA is working with manufacturers of the NBS furnace elements to research better materials that can be used for longer service life **

**Notes:**
Apparently the drawing found in report NISTIR 4917 is thought to be the most recent authoritative document, however, has no tolerances specified.

This may be the reason for the variability in the manufacturing process. 

The manufacturer has been contacted and we are actively working together to resolve this issue

The following  photo’s illustrate the lack of heating in the center of the furnace coil

## NBS Photometric System Round Robin

**FAA is currently conducting a round robin check out of the NBS Photometric system using neutral density light filters**
**These filters provide a linearity check of five data points**

**Notes:**
Basically...
The ambiguity in the data has put these tests on the hot seat

## NBS Photometric System Round Robin

**Tests are conducted without furnace heat or pilot burner operation**
**After zeroing then spanning the system, optical density readings are obtained by gradually sliding the filter over the lower glass panel in the chamber**
**Information on the light filters can be found on the following web site through Edmund Optics**
- http://www.edmundoptics.com/onlinecatalog/DisplayProduct.cfm?productid=1523
**Please contact me if your Lab would like to participate**

## Next Steps

**FAA is in the process of updating **_**Chapter 6**_** of the FAA Handbook (NBS)**
- Main focus will address such issues as furnace specification, Heat flux gage/Radiometer use and photometric system
- Comments on Chapter 6 will be accepted through 8/1/2008
- Chapter 5 (OSU) to follow
**FAA Contact Information:**
- Michael Burns @ _[mike.burns@faa.gov](mailto:mike.burns@faa.gov)__ _
- +1 (609) 485-4985

**Notes:**
The FAA will begin the process of updating Chapter 6 of the Handbook. 

Main focus will address furnace specs, heat flux measurement issues and the photometric system

Comments will be accepted from now until shortly after the next materials meeting

As a reminder please submit all findings of the internal review no later than 6/1/2008

## QUESTION & ANSWER

**   ****ANY QUESTIONS, COMMENTS OR SUGGESTIONS?**