FAA Composite Plan and Associated Research Topics - Presented to AMTAS By Cindy Ashforth, FAA November 6, 2019
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FAA Composite Plan and Federal Aviation
Administration
Associated Research Topics
Presented to AMTAS
By Cindy Ashforth, FAA
November 6, 2019
FAA Composite Plan • In use since FY14 • A short (
FY19 FAA Composite Plan Proposed List of
Initiatives (as of 5/2019) Changes
from last
Continuous Operational Safety Certification Efficiency (CE) Workforce Education (WE) approved
(COS) version in
CE A: Fatigue & Damage Tolerance red
COS A: Bonded Structure WE A: Workforce Training
Substantiation
WE B: Industry Training and
COS B: Closed CE B: Closed
International Outreach
COS C: Failure Analysis of CE C: Composite Structural
Composites Subjected to Fire Modifications Defines mitigating
actions (Deliverables) for
Document that summarizes CE D: Composite Quality Assurance the FAA - rulemaking,
potential safety risks and policy, guidance, and
opportunities for CE E: Bonded Structure Guidance
training materials – and
standardization (Initiatives) industry
CE F: General Composite Structure
associated with the use of
Guidance
composites in aviation
products CE G: Engine Applications Guidance
CE H: Composite TSO
November 5, 2019 FAA Research Overview Federal Aviation 3
AdministrationContinued Operational Safety (COS) Initiatives
• Two COS items in the Composite Plan:
A. Bonded Structure
• Bonded repairs
• Bond quality control
• Sandwich disbond growth
B. Closed
• Was HEWABI (high energy wide area blunt impact), which is closed after release
of a transport policy and internal webinar. Follow-on tasks for research and industry
documentation are moved to initiative CE A for fatigue and damage tolerance.
C. Failure analysis of composites subject to fire
November 5, 2019 FAA Research Overview Federal Aviation 4
AdministrationBeing asked: Why duplicate
COS Items work? Why can’t a standards
group directly publish MOC
COS A: Bonding content?
Bonding safety Support CMH-17 to publish Volumes 1 and 3 Rev H with new content on bonding, Fall 2021
risks include (includes research funds)
bonded repairs, Develop a Short Course for Bonded Repair Design, Substantiation, and Approval based on CMH-
bondline 17, Fall 2022
durability* and
sandwich disbond Create new AC or update AC 20-107B with additional bonding content, Draft Spring 2023
growth Support CMH-17 to publish Volume 6 Rev B with new content on sandwich structure, Spring 2023
*additional new (includes research funds)
rotorcraft
emphasis Create new AC or update AC 20-107B with additional sandwich content, Draft Spring 2024
COS C: Failure Analysis of Composites Subjected to Fire
Can we determine if there Fund research FY19-FY22
was a structural failure after
Publish update to Composite Failure Analysis Handbook (joint publication between the
an accident and post-
FAA and Air Force, last updated 1995) FY2023
impact fire?
November 5, 2019 FAA Research Overview Federal Aviation 5
AdministrationResearch that Supports COS Initiatives
• Moisture Diffusion in Sandwich Composites
• Effect of Surface Contamination on Composite Bond Integrity and
Durability Project
• Durability of Adhesively Bonded Joints for Aircraft Structures Project
• Durability of Bonded Aerospace Structures
• Improving Adhesive Bonding of Composites Through Surface
Characterization
• Nanomechanical Characterization of Adhesive Bondlines
November 5, 2019 FAA Research Overview Federal Aviation 6
AdministrationCertification Efficiency Initiatives
• Certification Efficiency (CE) initiatives capture best industry practices via regulatory
guidance and industry standards documents.
– Goal is to standardize methods to certify composite structures and repairs which will address the current industry practice of
using proprietary databases and advanced procedures.
• Seven CE initiatives
A. Fatigue and Damage Tolerance Substantiation
B. Closed
• Was Advanced Composites Maintenance – the two deliverables are no longer supported by AFS
C. Composite Structural Modification
D. Composite Quality Control
E. Bonded Structure Guidance
F. General Composite Structures Guidance
G. Engine Installation Guidance
H. Material TSO
• Additional standardization activities in the area of transport crashworthiness, fuel tank
lightning protection, and composite flammability
These FAA initiatives have some components specific to composites, but are not managed as part of the
composite plan
November 5, 2019 FAA Research Overview Federal Aviation 7
AdministrationCan/Should all
Certification Efficiency Items information go in an
industry publication?
CE A: Fatigue and Damage Tolerance
F&DT engineering Policy on interpreting existing 25.571 amdt for composite structure, TBD (AIR-675 deliverable)
protocols for composite
Support 25.571 ARAC Report, due 12/2019
aircraft structures differ
significantly from metal Revised 25.571 and associated guidance (may include AC 20-107B update), Draft 12/2020
engineering practices;
Ongoing research to supplement documentation in CMH-17, FY19-FY23
hybrid structures an
additional complexity
CE C: Composite Modifications
New applicants modifying critical Identify standards organization to publish portions of the content, 12/2019
composite structures, such as with
Support standards organization to publish portion of the content already
installation of antennas on 787 or A350
written for the AC, Date TBD
aircraft. Safety risk with new applicants do
not have experience in modifying critical Publish new AC on composite modifications that will summarize key points
composite structure, and FAA offices have from industry publication highlighting what to worry about and why, Date
requested guidance TBD to correlate with industry document
November 5, 2019 FAA Research Overview Federal Aviation 8
AdministrationCertification Efficiency Items
CE D: Composite Quality Assurance
Recent composite Research report on latest manufacturing techniques and associated key characteristics and
manufacturing key process parameters, Draft summer 2019
techniques may not be Create an appendix in AC 21-43 with unique considerations for composite quality system
able to utilize traditional oversight and cancel ACs 21-26 and 21-31, Draft winter 2020
quality control methods,
Current QC ACs have Identify gaps in M&P guidance from canceling QC ACs and if so, develop plan to supplement
type design information advanced M&P policy, AC 20-107 and/or industry standards (most likely CMH-17), Spring 2020
and 2x.605 MOC
CE E: Structural Bonding
– Same as COS A, but from a certification best practices / cert efficiency perspective
CE F: General Composite Guidance
With evolving/advancing composite Revise AC 20-107, “Composite Aircraft Structure,” to incorporate advanced
technology and expanding composite technologies and lessons learned, draft Spring 2024 (timed to coincide
composite applications, AC 20-107 with sandwich structure update under COS A / CE E)
“Composite Aircraft Structure” • Will follow CMH-17 Volume 3 Rev H and Volume 6 Rev B
requires revision • Will include latest lessons learned from research
November 5, 2019 FAA Research Overview Federal Aviation 9
AdministrationCertification Efficiency Items
CE G: Engine Guidance
Engine cert projects with Held CSTA workshop on engine applications and identify scope of engine AC,
composites have been managed on September 2019
a case-by-case basis by adapting Write a new AC for composite engine applications, that refers to AC 20-107B, but
AC 20-107B for composite aircraft puts in context of engine applications
structure. Unique concerns with
engines warrant individualized Engage engine industry with CMH-17 CMC and PMC coordination groups by
guidance holding joint meeting summer 2020
November 5, 2019 FAA Research Overview Federal Aviation 10
AdministrationResearch that Supports CE Initiatives
Failure of Notched Laminates Under Out-of-Plane Bending CE A
Evaluation of Parameters Used in Progressive Damage Models CE A
Development and Evaluation of Fracture Mechanics Test Methods for Sandwich
CE A
Composites - Damage Tolerance Test Method Development
Moisture Diffusion in Sandwich Composites CE A
Development of a Building Block Approach for Crashworthiness Testing N/A
Effect of Surface Contamination on Composite Bond Integrity and Durability
CE E
Project
Durability of Adhesively Bonded Joints for Aircraft Structures Project CE E
Durability of Bonded Aerospace Structures CE E
Improving Adhesive Bonding of Composites Through Surface Characterization CE E
Nanomechanical Characterization of Adhesive Bondlines CE E
Certification of Discontinuous Fiber Composite Material Forms for Aircraft
CE F, CE D
Structure
November 5, 2019 FAA Research Overview Federal Aviation 11
AdministrationNew
Certification Efficiency Items proposed
initiative
since 9/2018
CE H: Composite TSO
New initiative for development of basic Hold workshop to gauge industry interest and identify a standards organization(s) to
material data plus optional advanced work with, Winter 2019
material data and/or design tools. Allows Identify if any standards organization documentation is required, and scope working
companies to demonstrate technology agreement(s), Spring 2020
readiness outside of a certification project. Draft Minimum Performance Standard, TSO, and associated guidance, Winter 2021
November 5, 2019 FAA Research Overview Federal Aviation 12
AdministrationWhy do we need a TSO?
• Under the current system, we do not open certification projects for
development of composite data
• Some DAHs open projects to develop allowables and associated
tools, then cancel the project
– Data, however, is FAA approved and can be applied to other projects, when shown to
be applicable
• Other parties have no avenue to develop data that is approved by the
FAA
– Some basic material data may be generated under NCAMP system accepted by the
FAA, but that ties applicants to one testing house
– No higher-level data can be developed and accepted by the FAA (i.e., no conformity or
witnessing without a project number)
November 5, 2019 FAA Research Overview Federal Aviation 13
AdministrationNew TSO System
• Parties could develop data that would be approved by the FAA
without a certification project
– The data would be restricted to a well-documented design space
– Certification activities are still required in order to use the material and data – it has to
be shown to be applicable to the project; however, the tests used to develop the data
would not have to be re-performed with project numbers, conformity, and witnessing
(this is managed under the TSOA quality system)
– Brings parity to third parties so they can develop data in an economical method, the
same as current DAHs
• There would be a significant advantage to the FAA to receive data
packages with the TSO application that describe the limitations of the
data – a learning tool and design guide
November 5, 2019 FAA Research Overview Federal Aviation 14
AdministrationWhat is it?
• We are considering developing a new TSO and associated
guidance for composite materials
– Guidance is essential in order to implement the TSO, since it is a new
concept
• Addresses multiple segments of the industry:
– Material suppliers
– Companies who want to develop data that they can get credit for,
independent of an FAA certification project
• Includes development of basic material data plus optional
advanced material data and/or analytical tools
November 5, 2019 FAA Research Overview Federal Aviation 15
AdministrationCandidate TSO Content
• There could be three classes of data
1. Basic lamina-level M&P control data
• NCAMP-style data
• Requires a single material and process specification
• Could be developed by a material manufacturer (e.g., prepregger) or an end-user (perhaps
to develop data for a different cure process)
• TSO would reference existing published test standards and statistical methods to generate
this data
2. Advanced laminate or detailed design data
• Class 1 data is a prerequisite
• Likely developed by an end-user (such as a partner responsible for design or supplier to
propose an alternative design) for unique design details (e.g., structural joints, effects of
defects and strength after impact) above the base lamina level used for material control
• TSO would not prescribe test methods (i.e., no existing industry standards)
November 5, 2019 FAA Research Overview Federal Aviation 16
AdministrationCandidate TSO Content
• There could be three classes of data (cont.)
3. Tools that use the data from 1 and/or 2
• Class 1 or 2 is a prerequisite – design and analysis tools must be tied to material control and
test data developed under TSO
• Allows development of analytical tools (e.g., closed-form solutions or FEM) to use the
properties developed in 1 or 2
• Must include documentation of HOW to use the data and LIMITATIONS for the data
– Limitations are in addition to the M&P restrictions and could include design details (radii, thickness),
loading limitations (e.g., stringer spacing, joint details) or other design constraints (e.g.,
requirements, limits, criteria)
• Essentially creating a stand-alone design guide for a given material
system, manufacturing process, and design and installation details
November 5, 2019 FAA Research Overview Federal Aviation 17
AdministrationWorkforce Education Initiatives
• An essential component for COS and CE is a comprehensive
educational development program
• Successful composite safety and certification oversight is dependent
upon our workforce being knowledgeable of both basic and advanced
composite technologies and terminologies
– Includes International Standardization and Outreach
• Reorganized into two activities – internal FAA training and external
outreach/training
– Continuing to update/maintain training classes for AFS, ACO and MIDO workforces
– All outreach activities, including workshops, documented under this initiative
November 5, 2019 FAA Research Overview Federal Aviation 18
AdministrationWorkforce Education Initiatives
FAA Facilitator Industry Sponsor
FAA composite training supports three
segments of our workforce: engineering,
Education Development
Education Development
Specialized Training
manufacturing and maintenance
Compliments training available in industry Safety Awareness
and academia
Introduction
Incl. three levels of competency: FAA Sponsor
Degree of Involvement
Industry Support
And Investment
– Introduction (“Composites 101”)
– Safety Awareness (courses for each functional discipline)
• Skills needed for FAA workforce supporting composite applications
– Specific Skills Building (most courses developed by the industry)
• Specialized skills needed in the industry and some FAA experts
November 5, 2019 FAA Research Overview Federal Aviation 19
AdministrationWorkforce Education Items
WE A: Bonding
The FAA has developed Updated CMfgT course offered through WSU with revised content, lesson plans and a
composite training for ACO job aid, Fall 2020 (coordinate with revised AC 21-43 under initiative CE C)
engineers, MIDO inspectors Updated CSET course offered through WSU with revised content, lesson plans and a
and FSDO inspectors. All job aid, 12/2019
classes require periodic
updates. Coordinate with AFS to submit request to update CMT course offered through Abaris,
Fall 2019
WE B: Industry Training and International Outreach
Industry workforce development is Jointly host an educational workshop with an industry partner, winter or spring
an important educational initiative, 2020
separate from internal education Deliver certification tutorial and composite training at multiple venues, FY19-20
November 5, 2019 FAA Research Overview Federal Aviation 20
AdministrationQuestions
November 5, 2019 FAA Research Overview Federal Aviation 21
AdministrationReminder - Composite Research Topics
• Under Structural Integrity of Composites research group, we create
research requirements by top-level subject
– Think of as “buckets” projects fit within
• For FY2020, the subjects are:
– SIC.1: Damage Tolerance of Composite Structures
– SIC.2: Composite Maintenance Practices
– SIC.12: Continued Operational Safety (COS) and Certification Efficiency (CE) for
Emerging Composite Technologies
– SIC.14 Certification and Maintenance Protocols for Bonded Joints
November 5, 2019 FAA Research Overview Federal Aviation 22
AdministrationFor Discussion
• Be thinking about:
– What kind of projects you would like to do?
– What “bucket” would it would fit in, or do we need a new one?
– Will it support the composite plan?
– What role will the research play?
1. Evaluate new tools and techniques proposed by applicants
2. Provide publically available data where none exists that supports continued
operational safety (support publishing lessons learned)
3. Answer specific questions related to service events
4. Develop tools to promote standardization and increase certification efficiency
November 5, 2019 FAA Research Overview Federal Aviation 23
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