9/17/2003 1LRM Spec Review LRM Material and Process Spec Review Cindy Cole Certification Manager The...

9/17/2003 1LRM Spec Review

LRM Material and Process LRM Material and Process Spec ReviewSpec Review

Cindy ColeCindy Cole

Certification ManagerCertification Manager

The Lancair CompanyThe Lancair Company


GeneralGeneral

We don’t perform LRM at Lancair, but we We don’t perform LRM at Lancair, but we have investigated it. We do perform have investigated it. We do perform structural wet layup.structural wet layup.

Most comments are picky detailsMost comments are picky details Some are based on our ACO’s Some are based on our ACO’s

requirements for material database requirements for material database reportsreports


TerminologyTerminology I was very confused on the term ‘batch I was very confused on the term ‘batch

acceptance.’ Spec must differentiate:acceptance.’ Spec must differentiate: Supplier Quality Assurance performed by the Supplier Quality Assurance performed by the

fiber manufacturerfiber manufacturer Receiving tests performed by fabric Receiving tests performed by fabric

manufacturer manufacturer Quality assurance tests performed by the Quality assurance tests performed by the

material manufacturer (on mixed resin batches material manufacturer (on mixed resin batches and fabrics)and fabrics)

Receiving tests performed by the end-user (aka Receiving tests performed by the end-user (aka part producer) on resin and fabricpart producer) on resin and fabric

Tests performed by the end-user as in-process Tests performed by the end-user as in-process verificationverification


TerminologyTerminology To me ‘acceptance’ should indicate ‘when it comes in the To me ‘acceptance’ should indicate ‘when it comes in the

door.’ I believe the term ‘quality assurance’ should be door.’ I believe the term ‘quality assurance’ should be used in place of ‘acceptance’ testing by the base material used in place of ‘acceptance’ testing by the base material manufacturers after they have made their product. manufacturers after they have made their product.

The term “Equivalence” is used for different things. The term “Equivalence” is used for different things. Section 4.3 of Material Spec is “Equivalency Baseline Section 4.3 of Material Spec is “Equivalency Baseline Enhancement.” This should be retitled “Database Enhancement.” This should be retitled “Database Enhancement” or something similar to distinguish it Enhancement” or something similar to distinguish it from equivalence testing performed by an end-user to from equivalence testing performed by an end-user to show they can use properties developed by the material show they can use properties developed by the material supplier.supplier.

The Glossary should include terms like Batch, Batch The Glossary should include terms like Batch, Batch Acceptance, Equivalence, etc., that may be defined in the Acceptance, Equivalence, etc., that may be defined in the text of the document, but should be defined in the text of the document, but should be defined in the glossary as well.glossary as well.


Material Specification, Material Specification, LRM Processes and LRM Processes and

MaterialsMaterials Figure 2.1 (1.1 in the process Figure 2.1 (1.1 in the process

specification) flow chart should not have a specification) flow chart should not have a line between the Fiber Reception/Storage line between the Fiber Reception/Storage and Resin Mixing, nor between the Resin and Resin Mixing, nor between the Resin Reception/Storage and Preform Assembly Reception/Storage and Preform Assembly (unless you consider Tackifiers to be (unless you consider Tackifiers to be Resin).Resin).


Material Specification, Material Specification, LRM Processes and LRM Processes and

MaterialsMaterials Section 2.2 lists materials that are typically not Section 2.2 lists materials that are typically not

controlled by their own material specification, controlled by their own material specification, but rather by a qualified products list. We have but rather by a qualified products list. We have had to put mold release agents into a material had to put mold release agents into a material specification which include receiving inspection specification which include receiving inspection testing. Not sure what is meant by ‘adhesives’ testing. Not sure what is meant by ‘adhesives’ in this section.in this section.

Figure 3 shows tackified fabric as part of the Figure 3 shows tackified fabric as part of the material procurement spec. I would have material procurement spec. I would have expected this to be part of the material expected this to be part of the material acceptance spec. Materials aren’t purchased in acceptance spec. Materials aren’t purchased in preforms, are they?preforms, are they?


Material Specification, Material Specification, Development of Material Development of Material

ControlsControls Section 3.3, titled Part Producer Section 3.3, titled Part Producer

Responsibilities for Material use in Structural Responsibilities for Material use in Structural Design, should include more information on Design, should include more information on other tests for qualification of a material other tests for qualification of a material (lightning protection, compatibility with (lightning protection, compatibility with secondary adhesives, etc.)secondary adhesives, etc.)

Our ACO has requested that the material Our ACO has requested that the material database reports have specific wording database reports have specific wording regarding the limitations of the data. If we regarding the limitations of the data. If we want to work that into the specification, this want to work that into the specification, this may be the place to do it.may be the place to do it. This report provides material data that may be used This report provides material data that may be used

in Part 23 aircraft design, including B-Basis values in Part 23 aircraft design, including B-Basis values that meet the requirements of 23.613 taking into that meet the requirements of 23.613 taking into account environmental factors per 23.603. account environmental factors per 23.603.


Material Specification, Material Specification, Development of Material Development of Material

ControlsControls Section 3.3 recommends “that the end-Section 3.3 recommends “that the end-

user perform the purchaser batch user perform the purchaser batch acceptance tests on panels cured using acceptance tests on panels cured using the material supplier’s baseline cure the material supplier’s baseline cure process.” I disagree. Receiving process.” I disagree. Receiving Inspection should be performed using the Inspection should be performed using the same cure cycle that the parts will be same cure cycle that the parts will be made with. In practice it won’t work at made with. In practice it won’t work at our facility to have a separate cure cycle our facility to have a separate cure cycle just for receiving inspection.just for receiving inspection.


Material Specification, Material Specification, Qualification RequirementsQualification Requirements

Section 4.2 recommends a check for Section 4.2 recommends a check for maximum Tg. Is this really something to maximum Tg. Is this really something to check?check?

Section 4.3 Item 1 says the material Section 4.3 Item 1 says the material equivalency and batch acceptance equivalency and batch acceptance requirements should be recalculated and requirements should be recalculated and the specification updated. I think it the specification updated. I think it should specifically say in this step that the should specifically say in this step that the B-Basis design values are NOT changed.B-Basis design values are NOT changed.


Material Specification, Material Specification, Qualification RequirementsQualification Requirements

Section 4.6.3 says Level 2 changes can be Section 4.6.3 says Level 2 changes can be approved with less than the full equivalency test approved with less than the full equivalency test plan required for a Level 3 change. So what is plan required for a Level 3 change. So what is required?required?

Section 4.6.4 says that a full equivalency test Section 4.6.4 says that a full equivalency test program is required per AR-03/19 for a Level 3 program is required per AR-03/19 for a Level 3 change. I haven’t seen this document, but if it is change. I haven’t seen this document, but if it is the same as AR-00/47, it requires one batch with 8 the same as AR-00/47, it requires one batch with 8 replicates for strength and 4 for modulus. Section replicates for strength and 4 for modulus. Section 4.6.4 further states that “Testing to validate Level 4.6.4 further states that “Testing to validate Level 3 changes should involve a minimum of three 3 changes should involve a minimum of three batches…” Appears to be in conflict.batches…” Appears to be in conflict.


Material Specification, Material Specification, Resin ProcurementResin Procurement

Section 6.3.2 says “None of the tests in Section 6.3.2 says “None of the tests in Table 1 are recommended for batch Table 1 are recommended for batch acceptance testing” yet the footnote on acceptance testing” yet the footnote on Table 1 identifies some tasks as Table 1 identifies some tasks as ‘acceptance tests.’‘acceptance tests.’

Table 2 recommends cured resin tension Table 2 recommends cured resin tension test. Wouldn’t compression be more test. Wouldn’t compression be more relevant?relevant?

Section 6.3.5 is the PCD for resins, yet it Section 6.3.5 is the PCD for resins, yet it includes references to fabric.includes references to fabric.



Section 6.4.2.4 ( typo, listed as 6.4.3.4) Section 6.4.2.4 ( typo, listed as 6.4.3.4) says that replacement data is only allowed says that replacement data is only allowed if (1) test abnormality, (2) statistical if (1) test abnormality, (2) statistical outlier, outlier, andand (3) bad specimen prep or (3) bad specimen prep or conditioning. I believe that should be conditioning. I believe that should be oror..

Retest section should be specifically Retest section should be specifically identified as pertaining to both supplier identified as pertaining to both supplier and part producer testing.and part producer testing.

Paragraph three references prepregParagraph three references prepreg



Section 6.4.3 requires two copies of certs. Section 6.4.3 requires two copies of certs. Why?Why?

Section 6.4.5 says the specification should Section 6.4.5 says the specification should define the requirements for certifying a test define the requirements for certifying a test lab. I don’t think that should go in each lab. I don’t think that should go in each material specification. Belongs in a material specification. Belongs in a separate guidance document, or nowhere. separate guidance document, or nowhere. Test lab certification is left to the Quality Test lab certification is left to the Quality Department at Lancair, just like any other Department at Lancair, just like any other vender approval (no type design vender approval (no type design requirements).requirements).



Section 6.7 says that batches rejected by a Section 6.7 says that batches rejected by a purchaser should not be rerouted to other purchaser should not be rerouted to other purchasers. We should allow a way for the purchasers. We should allow a way for the material supplier to sell to a different material supplier to sell to a different customer with different requirements (e.g. customer with different requirements (e.g. sports industry). Can this be reworded?sports industry). Can this be reworded?


Material Specification, Material Specification, Fabric ProcurementFabric Procurement

Section 7.1 discusses ‘cure conditions.’ Is Section 7.1 discusses ‘cure conditions.’ Is this applicable to fabrics?this applicable to fabrics?

Section 7.3.3 is the PCD for fabric, but Section 7.3.3 is the PCD for fabric, but discusses resin.discusses resin.

Section 7.4.2.2 references cured and Section 7.4.2.2 references cured and uncured materialsuncured materials


Material Specification, Material Specification, Cured Material AcceptanceCured Material Acceptance

Table 6 may be easier to understand if it Table 6 may be easier to understand if it were broken into three tables that were broken into three tables that corresponded to text descriptions of (1) corresponded to text descriptions of (1) IMQ testing (2) Receiving Inspection IMQ testing (2) Receiving Inspection testing and (3) Database Enhancement testing and (3) Database Enhancement testing, with frequencies given for each.testing, with frequencies given for each.

Section 8.3.4.4 should perhaps reference Section 8.3.4.4 should perhaps reference foam instead of honeycomb core. foam instead of honeycomb core. Mentions prepreg. (recommend search Mentions prepreg. (recommend search and replace)and replace)


Material Specification, Material Specification, Cured Material AcceptanceCured Material Acceptance

Should the laminate tests include planned Should the laminate tests include planned variations in cure cycle, resin content, and variations in cure cycle, resin content, and hardener content?hardener content?

As shown in Figure 4, was it considered to As shown in Figure 4, was it considered to forego performing the Batch Acceptance forego performing the Batch Acceptance (receiving) tests and instead perform only the (receiving) tests and instead perform only the Batch Release Tests?Batch Release Tests? Goal should be for it to be the responsibility of the Goal should be for it to be the responsibility of the

supplier to provide a good product and prove it. supplier to provide a good product and prove it. (i.e. not the responsibility of the end-user to ensure (i.e. not the responsibility of the end-user to ensure they received good material) Responsibility of the they received good material) Responsibility of the end-user to provide a good part and prove it.end-user to provide a good part and prove it.


Material Specification, Material Specification, Cured Material Cured Material

AcceptanceAcceptance Section 8.4.2.2, Constituent Receiving Section 8.4.2.2, Constituent Receiving Inspection Tests, copies the material Inspection Tests, copies the material procurement spec. Does it belong here?procurement spec. Does it belong here?

Section 8.4.2.4, Part Acceptance Tests, Section 8.4.2.4, Part Acceptance Tests, recommends only performing a test on excess recommends only performing a test on excess resin to validate proper cure, when the resin to validate proper cure, when the materials have batch release testing prior to materials have batch release testing prior to use. What kind of test should that be?use. What kind of test should that be?

8.4.2.5, Retest, says to inform end-users of a 8.4.2.5, Retest, says to inform end-users of a material batch for which retests were material batch for which retests were performed. Is this applicable to the material performed. Is this applicable to the material acceptance spec?acceptance spec?


Process SpecificationProcess Specification

Should Section 2.3 on Materials be Should Section 2.3 on Materials be included, or just reference the material included, or just reference the material specification?specification?

Bagging materials should be controlled in Bagging materials should be controlled in some manner, perhaps in Section 2.4some manner, perhaps in Section 2.4

Section 2.7.1 says that at least two Section 2.7.1 says that at least two thermocouples should be used for each thermocouples should be used for each panel. Perhaps more useful to define a panel. Perhaps more useful to define a ratio for number of thermocouples to ratio for number of thermocouples to panel area.panel area.


Process SpecificationProcess Specification

I recommend Section 2.8.2, Inspection I recommend Section 2.8.2, Inspection and Process Monitoring, references the and Process Monitoring, references the material specification or the material material specification or the material specification references this one rather specification references this one rather than put in both places.than put in both places.

Section 2.8.3, Panel Inspection, includes a Section 2.8.3, Panel Inspection, includes a check on panel thickness. Is this unique check on panel thickness. Is this unique to LRM or also in prepreg? If values are to LRM or also in prepreg? If values are normalized by ply thickness, is this normalized by ply thickness, is this necessary?necessary?


RecommendationsRecommendations Table of standard tolerancesTable of standard tolerances Flammability TestingFlammability Testing Effects of lightning mesh (included in the Effects of lightning mesh (included in the

samples or not)samples or not) For us, Environmental/Variability Factors For us, Environmental/Variability Factors

are a big part of what we get out of are a big part of what we get out of laminate tests. Can that be discussed in laminate tests. Can that be discussed in this document?this document?E/V Factor = E/V Factor = Mean Strength at Test Mean Strength at Test

EnvironmentEnvironment B-Basis Strength at HWB-Basis Strength at HW

9/17/2003 1LRM Spec Review LRM Material and Process Spec Review Cindy Cole Certification Manager The...

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