Tim Marker Laboratory & Full Scale Testing of Non Traditional Lightweight Aircraft Seats FAA Technical Center
Dec 17, 2015
Tim Marker
Laboratory & Full Scale Testing ofNon Traditional Lightweight Aircraft Seats
FAA Technical Center
Problem: Next Generation aircraft seats utilizing lighter materials in theirconstruction 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 underrealistic 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 assemblyprocesses (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 consistingof 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
•FAATC randomly selects 6 sets of cushions to conductlab-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
Seat
Initial Weight Bottom Cushion
(lbs)
Initial Weight Bottom Cover (lbs)
Initial Weight Back
Cushion (lbs)
Initial Weight Back Cover (lbs)
Initial Weight Total (lbs)
Final Weight Total (lbs)
Weight Loss (%)
Avg Weight Loss (%)
2.25 0.75 1.48 0.78 5.26 4.94 6.032.25 0.75 1.48 0.78 5.26 4.81 8.542.25 0.75 1.48 0.78 5.26 4.73 10.042.19 0.72 1.47 0.78 5.16 4.75 7.952.19 0.72 2.08 0.78 5.77 5.35 7.282.21 0.80 1.5 0.78 5.29 4.87 7.94
2.21 0.72 1.5 0.78 5.21 4.790 8.062.22 0.74 1.52 0.79 5.27 4.970 5.692.22 0.75 1.56 0.79 5.32 4.990 6.20
0.55 0.71 0.42 0.77 2.45 2.07 15.500.54 0.69 0.41 0.75 2.39 2.01 15.890.54 0.69 0.41 0.75 2.39 1.96 17.990.54 0.70 0.41 0.75 2.40 1.80 25.000.54 0.70 0.41 0.76 2.41 1.98 17.780.54 0.70 0.41 0.75 2.40 2.02 15.86
1.86 0.74 1.19 0.78 4.56 4.06 10.961.83 0.74 1.18 0.78 4.54 4.01 11.671.83 0.74 1.15 0.78 4.50 3.98 11.561.86 0.74 1.15 0.78 4.55 3.98 12.531.86 0.74 1.18 0.78 4.58 4.02 12.231.83 0.74 1.17 0.78 4.52 3.90 13.72
1.48 0.56 1.05 0.60 3.68 3.07 16.621.46 0.55 1.06 0.57 3.64 3.23 11.211.46 0.54 1.06 0.60 3.65 3.28 10.101.46 0.54 0.95 0.57 3.52 3.10 11.841.42 0.55 1.05 0.58 3.60 3.21 10.951.44 0.55 1.03 0.58 3.60 3.21 10.95
1.01 0.55 0.80 0.60 2.97 2.57 13.330.98 0.55 0.79 0.58 2.91 2.52 13.410.99 0.54 0.83 0.58 2.94 2.54 13.700.99 0.54 0.83 0.58 2.94 2.54 13.701.00 0.56 0.83 0.57 2.97 2.58 12.990.99 0.55 0.84 0.58 2.97 2.57 13.33
Lightweight D 13.41
Lightweight A 18.00
Lightweight B 12.11
Lightweight C 11.94
Baseline 1 7.96
Baseline 2 6.65
Lab-Scale Test Results
PASS
PASS
FAIL
FAIL
FAIL
FAIL
Lab Scale Test ResultsLightweight A Seat Cushion
-5.0
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
1 2 3 4 5 6
Wei
gh
t L
oss
(%
)
Weight Loss Average = 18.00%
Bottom Cushion
Bottom Dress Cover
Back Cushion
Back Dress Cover
Lab Scale Test ResultsLightweight B Seat Cushion
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
1 2 3 4 5 6
Wei
gh
t L
oss
(%
)
Bottom Cushion
Bottom Dress Cover
Back Cushion
Back Dress Cover
Weight Loss Average = 12.11%
Lab Scale Test ResultsLightweight C Seat Cushion
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
1 2 3 4 5 6
Wei
gh
t L
oss
(%
)
Weight Loss Average = 11.94%
Bottom Cushion
Bottom Dress Cover
Back Cushion
Back Dress Cover
Lab Scale Test ResultsLightweight D Seat Cushion
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
1 2 3 4 5 6
Wei
gh
t L
oss
(%
)
Weight Loss Average = 13.41%
Bottom Cushion
Bottom Dress Cover
Back Cushion
Back Dress Cover
Laboratory Comparison of Lightweight Seats6 Test Average
0
5
10
15
20
25
30
35
40
Wei
gh
t L
oss
(%
)
Lightweight Seat A Lightweight Seat B Lightweight Seat C Lightweight Seat D
Bottom Cushion
Bottom Dress Cover
Back Cushion
Back Dress Cover
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 Materials0.25-Inch thick crushed-core Nomex honeycomb panels, meets 65/65
Aircraft-grade carpet, meets VBB
Test Execution
Test ArticleB707 fuselage, fully fire hardened interior
InstrumentationContinuous 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
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 @ 5:30
CO2 Extinguishing Agent applied to interior @ 6:30
Full-Scale Test Parameters
Fire hardened foam, no blocking layer, with 91/9 Wool/Nylon dress cover
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 coverWeight 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
Fire hardened foam, no blocking layer, with 91/9 Wool/Nylon dress cover
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 coverWeight 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 Parameters
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
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Baseline Seat Weight Loss (%)
Seat 1Seat 2Seat 3
Seat 4
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Lightweight Seat A Weight Loss (%)
Seat 1
Seat 2
Seat 3
Seat 4
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Lightweight Seat B Weight Loss (%)
Seat 1
Seat 2
Seat 3
Seat 4
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Lightweight Seat C Weight Loss (%)
Seat 1
Seat 2
Seat 3
Seat 4
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Lightweight Seat D Weight Loss (%)
Seat 1
Seat 2
Seat 3
Seat 4
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 lengthof test/suppression of the external fire, and not a good indicator of overallcushion performance.
Temperature, Fire Gas, and Smoke Levels
Seat 1 Temperatures
0
100
200
300
400
500
600
700
800
900
1000
0 60 120 180 240 300 360 420 480
Time (Seconds)
Tem
per
atu
re (
oF
)
Baseline Seat 1 Avg
Lightweight A Seat 1 Avg
Lightweight C Seat 1 Avg
Lightweight D Seat 1 Avg
Seat 2 Temperatures
0
200
400
600
800
1000
1200
1400
1600
0 60 120 180 240 300 360 420 480
Time (Seconds)
Tem
per
atu
re (
oF
)
Baseline Seat 2 Avg
Lightweight A Seat 2 Avg
Lightweight C Seat 2 Avg
Lightweight D Seat 2 Avg
Seat 3 Temperatures
0
200
400
600
800
1000
1200
1400
1600
0 60 120 180 240 300 360 420 480
Time (seconds)
Tem
per
atu
re (
oF
)
Baseline Seat 3 Avg
Lightweight A Seat 3 Avg
Lightweight C Seat 3 Avg
Lightweight D Seat 3 Avg
Seat 4 Temperatures
0
100
200
300
400
500
600
0 60 120 180 240 300 360 420 480
Time (Seconds)
Tem
per
atu
re (
oF
)
Baseline Seat 4 Avg
Lightweight A Seat 4 Avg
Lightweight C Seat 4 Avg
Lightweight D Seat 4 Avg
Mid Cabin Temperatures
0
50
100
150
200
250
300
350
400
0 60 120 180 240 300 360 420 480
Time (Seconds)
Tem
per
atu
re (
oF
)
Baseline MID Tree Avg
Lightweight A MID Tree Avg
Lightweight C MID Tree Avg
Lightweight D MID Tree Avg
Forward Cabin Temperatures
0
50
100
150
200
250
300
350
400
0 60 120 180 240 300 360 420 480
Time (Seconds)
Tem
per
atu
re (
oF
) Baseline FWD Tree Avg
Lightweight A FWD Tree Avg
Lightweight C FWD Tree Avg
Lightweight D FWD Tree Avg
Aft Cabin Temperatures
0
100
200
300
400
500
600
0 60 120 180 240 300 360 420 480
Time (Seconds)
Tem
per
atu
re (
oF
)
Baseline AFT Tree Avg
Lightweight A AFT Tree Avg
Lightweight C AFT Tree Avg
Lightweight D AFT Tree Avg
Cabin Area Heat Flux Level
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0 60 120 180 240 300 360 420 480
Time (Seconds)
Hea
t F
lux
(Btu
/ft2 s
ec)
Baseline Calorimeter Avg
Lightweight A Calorimeter Avg
Lightweight C Calorimeter Avg
Lightweight D Calorimeter Avg
Mid Cabin Smoke Level
0
10
20
30
40
50
60
70
80
90
100
0 60 120 180 240 300 360 420 480
Time (Seconds)
Lig
ht
Tran
smis
sio
n (
%)
Baseline MID Smokemeter Avg
Lightweight A MID Smokemeter Avg
Lightweight C MID Smokemeter Avg
Lightweight D MID Smokemeter Avg
Forward Cabin Smoke Level
0
10
20
30
40
50
60
70
80
90
100
0 60 120 180 240 300 360 420 480
Time (Seconds)
Lig
ht
Tran
smis
sio
n (
%)
Baseline FWD Smokemeter Avg
Lightweight A FWD Smokemeter Avg
Lightweight C FWD Smokemeter Avg
Lightweight D FWD Smokemeter Avg
Carbon Monoxide Level
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 60 120 180 240 300 360 420 480
Time (Seconds)
Car
bo
n M
on
oxi
de
(%)
Baseline Carbon Monoxide AvgLightweight A Carbon Monoxide AvgLightweight C Carbon Monoxide AvgLightweight D Carbon Monoxide Avg
Carbon Dioxide Level
0
1
2
3
4
5
6
7
8
9
10
0 60 120 180 240 300 360 420 480
Time (Seconds)
Car
bo
n D
ioxi
de
(%)
Baseline Carbon Dioxide AvgLightweight A Carbon Dioxide AvgLightweight C Carbon Dioxide AvgLightweight D Carbon Dioxide Avg
Oxygen Level
0
5
10
15
20
25
0 60 120 180 240 300 360 420 480
Time (Seconds)
Oxy
gen
(%
)
Baseline Oxygen AvgLightweight A Oxygen AvgLightweight C Oxygen AvgLightweight D Oxygen Avg
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
Total Seat Weight (lbs)
Average Ratio of Cushion Weight to Cover Weight
Corrected Allowable Weight
Loss (%)
Corrected Allowable Burn Length (Inches)
Less than 3 1.8 to 2.0 12 161.5 to 1.79 14 151.1 to 1.49 16 14.60 to 1.09 18 13
0 to .59 20 12
Seat
Initial Weight Bottom Cushion
(lbs)
Initial Weight Bottom
Cover (lbs)
Initial Weight Back
Cushion (lbs)
Initial Weight Back
Cover (lbs)
Initial Weight
Total (lbs)Final Total
(lbs)Weight
Loss (%)
Avg Weight Loss (%)
Ratio Cushion
Weight to Cover Weight
Average Ratio
Corrected Allowable Weight
Loss (%) Pass/Fail
2.25 0.75 1.48 0.78 5.26 4.94 6.03 2.442.25 0.75 1.48 0.78 5.26 4.81 8.54 2.442.25 0.75 1.48 0.78 5.26 4.73 10.04 2.442.19 0.72 1.47 0.78 5.16 4.75 7.95 2.442.19 0.72 2.08 0.78 5.77 5.35 7.28 2.852.21 0.80 1.5 0.78 5.29 4.87 7.94 2.35
2.21 0.72 1.5 0.78 5.21 4.790 8.06 2.472.22 0.74 1.52 0.79 5.27 4.970 5.69 2.442.22 0.75 1.56 0.79 5.32 4.990 6.20 2.45
1.86 0.74 1.19 0.78 4.56 4.06 10.96 2.011.83 0.74 1.18 0.78 4.54 4.01 11.67 1.981.83 0.74 1.15 0.78 4.50 3.98 11.56 1.961.86 0.74 1.15 0.78 4.55 3.98 12.53 1.981.86 0.74 1.18 0.78 4.58 4.02 12.23 2.001.83 0.74 1.17 0.78 4.52 3.90 13.72 1.97
1.48 0.56 1.05 0.60 3.68 3.07 16.62 2.181.46 0.55 1.06 0.57 3.64 3.23 11.21 2.241.46 0.54 1.06 0.60 3.65 3.28 10.10 2.211.46 0.54 0.95 0.57 3.52 3.10 11.84 2.161.42 0.55 1.05 0.58 3.60 3.21 10.95 2.171.44 0.55 1.03 0.58 3.60 3.21 10.95 2.17
1.01 0.55 0.80 0.60 2.97 2.57 13.33 1.590.98 0.55 0.79 0.58 2.91 2.52 13.41 1.560.99 0.54 0.83 0.58 2.94 2.54 13.70 1.620.99 0.54 0.83 0.58 2.94 2.54 13.70 1.621.00 0.56 0.83 0.57 2.97 2.58 12.99 1.610.99 0.55 0.84 0.58 2.97 2.57 13.33 1.61
0.55 0.71 0.42 0.77 2.45 2.07 15.50 0.650.54 0.69 0.41 0.75 2.39 2.01 15.89 0.650.54 0.69 0.41 0.75 2.39 1.96 17.99 0.650.54 0.70 0.41 0.75 2.40 1.80 25.00 0.650.54 0.70 0.41 0.76 2.41 1.98 17.78 0.650.54 0.70 0.41 0.75 2.40 2.02 15.86 0.65
10 Pass2.497.96
6.65 2.46 10 Pass
12.11 1.99 10 Fail
11.94 2.19 10 Fail
13.41 1.60 14 Pass
18.00 0.65 18 Pass
Lightweight D
Lightweight A
Baseline 1
Baseline 2
Lightweight B
Lightweight C
Cushion/Cover Ratio Vs. Weight Loss and Burn Length
0
5
10
15
20
25
0 to .59 .6 to 1.09 1.1 to 1.49 1.5 to 1.79 1.8 to 2.0
Cushion to Cover Weight Ratio
Wei
gh
t L
oss
(%
)
0
2
4
6
8
10
12
14
16
18
Bu
rn L
eng
th (
Inch
es)
Adjusted Allowable Weight Loss
Adjusted Allowable Burn Length