FAA AVS Federal Aviation Composite Plan & Related Research
FAA AVSComposite Plan &Related ResearchPresented to: AMTASBy: Cindy Ashforth and Larry IlcewiczDate: November 8, 2017Federal AviationAdministration
FAA Research Process Three years in advance, we in AVS propose topicsfor research– Under Structural Integrity of Composites, we createrequirements for buckets for subjects such as: Structural Integrity of BondsMaintenanceFatigue and Damage ToleranceAdvanced Materials and TestingCrashworthiness Year before execution we modify the requirementsas necessary, based on what we have learned inthe interimNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration2
FAA Research Process The FAA Technical Center turns our requirementsinto requests that go out to JAMS– Multiple line items / projects per “bucket” We have moved to a system where we expectdetailed project plans with milestones anddeliverables, and request written reports every yearthat are published by the technical center In FY16 and FY17, we had congressionallymandated additional funds which sponsor JAMSresearch that supports certification efficiency, morethan continued operational safety– We try to accelerate items identified in the RequirementsNovember 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration3
AVS Composite Plan The FAA’s mission is to “provide the safest,most efficient aerospace system in theworld.”– Safety is always our first priority Composite design and manufacturingoversight is performed by the AircraftCertification Service, which in turn is part ofthe Aviation Safety Office (AVS) of the FAA– AVS is comprised of 7 offices, including AircraftCertification (AIR) and Flight Standards (AFS)November 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration4
AVS Composite Plan The FAA has created an AVS Composite Plan toidentify and manage safety risks, opportunities tostandardize means of compliance, and promoteworkforce education– Seven-year plan updated annually– Depends on industry deliverables (e.g., CMH-17 and SAE)– Includes FAA research Three focus areas– Continued Operational Safety (COS)– Certification Efficiency (CE)– Workforce Education (WE) Priority is assigned to tasks based on issues thatpose the greatest safety threatsNovember 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration5
Overview FY2017Continuous OperationalSafety (COS)Red items are directly supported by FAA research(AMTAS and CECAM coordination expected)Green items are indirectly supported by FAA researchCertification Efficiency (CE)Workforce Education(WE)COS A: Bonded StructureCE A: Hybrid F&DTSubstantiationWE A: CompositeManufacturingTechnologyCOS B: HEWABI (HighEnergy, Wide-Area BluntImpact)CE B: Advanced CompositeMaintenanceWE B: CompositeStructures TechnologyCOS C: Failure Analysis ofComposites Subjected to FireCE C: Composite StructuralModificationsWE C: CompositeMaintenance TechnologyCE D: Composite QualityAssuranceCE E: Bonded StructureGuidanceCE F: General CompositeStructure GuidanceCE G: Engine GuidanceNovember 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration6
COS Initiatives Three COS items in the Composite Plan:A. Bonded StructureB. HEWABI (high-energy, wide-area, blunt impacts)C. Failure analysis of composites subject to fireNovember 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration7
COS A, Bonding The Bonding initiative encompasses threedistinct sub-subjectsPublished as a FAATechnical Center Report(Seaton & Richter), 20148– Bonded RepairsFrom Air ForceMP3 Mtg.Frank Zankar(NTSB, 2008)– Bond Quality Control– Sandwich Disbond GrowthIn-flight Rudder Failure(Large damage causing flutter)Air Transat Flight 961 [3/6/05]November 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration8
COS A, BondingItems in Italicsare Completed FAA DeliverablesØ PS-AIR-20-130-01 “Bonded Repair Size Limits” released11/2014– Published Chapter in Order 8900.1 “Flight StandardsInformation Management System” outlining Bonded RepairSize Limits– Published Advisory Circular (AC) 65-33, “Development ofTraining/Qualification Programs for Composite MaintenanceTechnicians” to include specific guidance on bonded structure– Short Course for Bonded Repair Design, Substantiation, andApproval FY2018Ø AC for Bonded Structure that includes Bonded Repair BestPractices FY2021Ø AC for Sandwich Structure FY2020November 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration9
COS A, Bonding Industry Deliverables and Research– Publication of the ACs is dependent on successful completion ofthe following documents by industry groups: Best Practices inBonded Repair (SAE), CMH-17 Repair Substantiation (CMH-17Rev H), Standards for Metal Bond Process QC (ASTM D3762),Test Standards for Disbond Growth (ASTM) and CMH-17 RiskMitigation Guidelines (CMH-17 Rev H)– Numerous FAA research projects on bonded and sandwichstructure are underway and planned for the next few years– FAA also researching current maintenance instruction practicesNovember 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration10
FAA Research SupportingCOS A, Bonding (includes sandwich structure) Improving Adhesive Bonding ofComposites through Surface Characterization Development and Evaluation of Environmental DurabilityTest Methods for Composite Bonded Joints Effect of Surface Contamination onComposite Bond Integrity and Durability Durability of Adhesively BondedAerospace Structure CACRC Depot Bonded Repair Investigation Environmental Factor Influence on Sandwich Bonded Repair TeardownNovember 7, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration11
COS B, HEWABIHigh-energy wide-area blunt impacts (HEWABI)Items in Italicsare Completed FAA DeliverablesØ PS-ANM-25-20 requiring HEWABI evaluation during thecertification of aircraft structures released 8/2017Ø Internal FAA webinar FY2017 Industry Deliverables and ResearchØ FAA has funded research in this areaØ The FAA will participate in the development of a chapter inCMH-17 specific to HEWABI to be used as future guidance forcomposite aircraft certification When webinar is completed, the initiative will beclosed– Follow up actions in CE ANovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration12
FAA Research SupportingCOS B, HEWABI Impact Damage Formation onComposite Aircraft Structures Non-Destructive EvaluationMethods for Detecting Major Damagein Internal Composite Structural ComponentsNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration13
COS C, Failure Analysis of SurfacesSubjected to Fire after Part Failure BackgroundØ Composite structure thatfailed in an accident may besubjected to fire, changingfailure surfaces andpotentially masking cluesthat could identify the rootcause for part failure or the FAA Deliverablesextent of damage– Failure Analysis FAA Research StartedHandbook FY2021(in-house at tech center)Left center attach point withportion of vertical stabilizerLeft rear attach point withportion of vertical stabilizerRight rear attach pointNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration14
Certification Efficiency Initiatives Certification Efficiency (CE) initiativescapture best industry practices viaregulatory guidance and industry standardsdocuments. Goal is to standardize methods to certifycomposite structures and repairs which willaddress the current industry practice ofusing proprietary databases and advancedprocedures.November 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration15
Certification Efficiency Initiatives Seven CE initiativesA.Hybrid Metallic/Composite Structure Fatigue and Damage ToleranceSubstantiationB. Advanced Composite MaintenanceC. Composite Structural ModificationD. Composite Quality ControlE. Bonded Structure GuidanceF. General Composite Structures GuidanceG. Engine Installation Guidance Additional standardization activities in the area of transportcrashworthiness, fuel tank lightning protection, andcomposite flammability–November 8, 2017These FAA initiatives have some components specific to compositesFAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration16
CE A, Hybrid Structure Background– Fatigue and damage tolerance(F&DT) engineering protocol forcomposite aircraft structures differsignificantly from metalengineering practices. Theseissues must be considered for thesubstantiation of most modernstructures that include acombination of composite andmetallic parts and assemblies.November 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration17
CE A, Hybrid StructureItems in Italicsare Completed DeliverablesØ Policy on interpretation of existing amendment 25.571 forcomposite structure FY2019Ø FAA “White Paper” 9/2016Ø A new rule defining fatigue and damage tolerance requirements forthe certification of composite transport aircraft FY2020Ø Associated guidance for new part 25 rule FY2020 Industry Deliverables and ResearchØ Publication of the policy is dependent on CMH-17 Rev H F&DTupdates and ASTM test standards for laminate damagepropagationØ All deliverables linked to the three-year ARAC Tasking formed1/26/2015 under the Transport Airplane Metallic and CompositeStructures Working GroupNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration18
FAA Research Supporting CE A,Hybrid Structure F&DT Environmental Factor Influence on CompositeDesign and CertificationDamage Tolerance Testing and AnalysisProtocols for Full-Scale Composite AirframeStructures under Repeated LoadingFailure of Notched Laminatesunder Out-of-Plane BendingDelamination/Disbond Arrest Featuresin Aircraft Composite Structures* Evaluation of Notch Sensitivity ofComposite Sandwich Structures*Composite impact damage tolerance(metrics, detectability, criticality)*Also supports COS A, Bonding Recently completedNovember 8, 2017FAA AVS Composite Plan and RelatedResearch Activities19Federal AviationAdministration
FAA Research Supporting CE B,Advanced Composite Maintenance CACRC Depot Bonded Repair Investigation– Round Robin Testing Bonded Repair Teardown StudiesNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration20
CE D, Quality AssuranceGuidance Deliverables– New AC that incorporates guidance on material andprocess specifications from AC 21-26, AC 21-31,and small airplane directorate policy PS-ACE 1002002-006 and AC 23-20, “Acceptance Guidance onMaterial Procurement and Process Specifications forPolymer Matrix Composite Systems” Draft due 12/2018, Final 12/2019 Industry Deliverables and Research– FAA-sponsored research into current process controlsFY2017 Research is behind schedule, likely affecting date of AC releaseNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration21
FAA Research Supporting CE D,Quality Assurance Guidance Advanced Fiber Reinforced PolymerComposite Materials Characterization Ceramic Matrix Composite (CMC)Materials Characterization Polymer-Based AdditiveManufacturing (PBAM) Characterization Discontinuous Fiber Composite StructuresNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration22
CE E, Bonded Structure Guidance Background– There is an existing part 23 policy memo covering bondedstructure material and process, control, design, analysis,testing, manufacturing, and repair techniques. The policy willbe expanded into an AC for all product types and there will bea companion AC for sandwich structure. Deliverables– AC for Bonded Structure that includes Bonded Repair BestPractices FY2021 (Note this is the same deliverable as COSInitiative A)– AC for Sandwich Structure FY2020 (Note this is the samedeliverable as COS Initiative A)– Other FAA guidance will be reviewed to determine effects fromloss of prescriptive rule 23.573 in the part 23 rewriteNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration23
FAA Research Supporting CE E,Bonded Structure Guidance All research associated with COS-ABonding (see Chart 11) Adhesive Qualification Characterization Bond Process QualificationCharacterizationNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration24
CE F, General CompositeStructure Guidance Background– With the evolving/advancing composite technology andexpanding composite applications, AC 20-107 “CompositeAircraft Structure” will require revision Deliverables– Revision to AC 20-107, “Composite Aircraft Structure,” toincorporate advanced composite technologies and lessonslearned FY2022 Industry Deliverables and Research– Will incorporate latest information from industry documentationand FAA research (see all previous charts)November 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration25
AMTAS Research Supporting CEF, General Composite Guidance Safety and Certification of Discontinuous FiberComposite StructuresSince this is general guidance, AMTASresearch that supports any of the othercomposite guidance will also have an influenceon updates to AC 20-107CNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration26
CE G, Engine InstallationGuidance Background– Polymer matrix composite (PMC) materials have beenapproved in several engine applications and now ceramicmatrix composite (CMC) materials are being approved as well.These approvals have been managed on a case-by-casebasis, adapting existing composite guidance for compositeaircraft structure. Unique concerns with engine applicationswould benefit from documenting standardized means ofcompliance for both PMC and CMC materials Deliverables– New AC on certification of composite materials (PMC andCMC) in engine applications 12/2019 (draft due 12/2018) Industry Deliverables and Research– FAA research on CMCsNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration27
FAA Research Supporting CE G,Engine Installation Guidance Ceramic Matrix Composite (CMC)Materials CharacterizationNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration28
Workforce Education Initiatives An essential component for COS and CE isa comprehensive educational developmentprogram Successful composite safety andcertification oversight is dependent uponour workforce being knowledgeable of bothbasic and advanced compositetechnologies and terminologiesNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration29
Workforce Education InitiativesEducation DevelopmentCourses to support airframeengineering, manufacturing andmaintenance functional disciplinesIncl. three levels of competency: FAA SponsorEducation DevelopmentFAA composite training strategy using existing courses, FAA CentersFAA Facilitatorof Excellence & industry supportIndustry SponsorSpecialized TrainingSafety AwarenessIntroductionDegree of InvolvementIntroduction (“Composites 101”)And InvestmentSafety Awareness (courses for each functional discipline)– Skills needed for FAA workforce supporting composite applicationsSpecific Skills Building (most courses developed by the industry)– Specialized skills needed in the industry and some FAA expertsIndustry Support All courses can be adjusted for classroom or internet(condensed badges/tutorials or full blackboard with discussion boards) Seeking industry partnerships & safety awareness standardsNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration30
Workforce Education Initiatives Three initiatives – developed by the FAA butavailable to industry as wellA. Composite Manufacturing TechnologyB. Composite Structures TechnologyC. Composite Maintenance Technology Additional activities supporting “composites 101”training and Composite DER designations Includes international outreach and standardization– Promote safety, technology transfer and maintaining a levelplaying fieldNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration31
WE A, Composite ManufacturingTechnology Background– The Composite Manufacturing Technology (CMfgT)course was first offered in spring 2015 Offered through Wichita State University– It will be updated with the new quality control ACcontent (CE D) Deliverables– Updated CMfgT course with revised content, lessonplans and a job aid 6/2020November 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration32
WE A, Composite ManufacturingTechnology FAA-Developed Course for FAA and IndustryWorkforce Goal:– To provide FAA Manufacturing Inspectors and Designees with atechnical background of composite manufacturing to a level thatallows them to better and more proactively identify deficiencieson the factory floor that have safety implications. Five “Badges” offered through Wichita State– 4 online Badges include 12 modules that roughly correlate tocomposite production workflow– 16 hours laboratory (onsite at Wichita State University) Includes an electronic job aid for later referenceNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration33
FAA’s Composite Manufacturing Course0.1. Introduction toComposites0.2. CompositeFactory Workflow1. Raw MaterialsManufacturing2. Transport,Incoming QCand Storage9. Handling andStorageCOURSE MODULES3. Tool Prep,Cutting, Layupand Bagging8. Paint andFinish 10. CommonManufacturing IssuesEach Blockhas slide content,assessment/test, andvideo linksNovember 8, 20177. Bonding andPart Assembly4. Cure andSolidification6. InspectFAA AVS Composite Plan and RelatedResearch Activities5. Trim and DrillFederal AviationAdministration34
WE B, Composite StructuresTechnology Background– The Composite Structural Engineering Technology(CSET) course will be updated every four years. Offered through Wichita State University– Update the structural DER seminar content on arecurring basis Deliverables– Updated CSET course with revised content, lessonplans and a job aid 12/2018 Significant revision and reformatting underway to removeredundancy and turn into multiple shorter courses fordifferent subjectsNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration35
FAA’s Composite Structural EngineeringTechnology (CSET) Course Top-level Course Objectives– Students will describe essential safety awareness issues associated withcomposite structural engineering important to safe composite aircraftproduct applications- Students will describe engineering principles of composite airframesubstantiation during all stages of aircraft product certification Updated Course Outline1.02.03.04.05.06.07.0Composite ApplicationsMaterial, Processing and Fabrication DevelopmentDesign DevelopmentStructural SubstantiationManufacturing Interface IssuesMaintenance Interface IssuesAdditional Considerations7.1 Flutter7.2 Crashworthiness7.3 Fire safety and fuel tank issues7.4 Lightning protectionNovember 8, 2017FAA AVS Composite Plan and RelatedResearch ActivitiesFederal AviationAdministration36
WE C, Composite MaintenanceTechnology Background– Revise Flight Standards Service’s course “CompositeAwareness for the Aviation Safety Inspector,” on afive year basis (was last updated in 2015)– Additional directed trainin
Federal Aviation Administration CE F, General Composite Structure Guidance Background –With the evolving/advancing composite technology and expanding composite applications, AC 20-107 “Composite Aircraft Structure” will require revision Deliverables –Revision to AC 20-107, “Composite Aircraft Structure,” to
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