Federal Aviation Administration NexGen Burner Update International Aircraft Materials Fire Test...

Federal AviationAdministrationNexGen Burner

Update

International Aircraft Materials Fire Test Working Group Meeting

October 21, 2009

Atlantic City, NJ

Burnthrough Update

IAMFTWG, Atlantic City, NJ2

Federal AviationAdministration

Outline

• Background• NexGen Burner Drawings• Recent findings

Burnthrough Update



What is a NexGen Burner?• The next generation (NexGen) burner was

designed by the FAA Technical Center to be used as an equivalent burner to the Park DPL 3400 which is no longer in production

• The NexGen burner relies on the same operating principles as the Park DPL 3400, which was designed for home heating purposes

– Oil burner fuel nozzle, 80°hollow cone, 6.0 gph– Air flow approx 1350 fpm exiting draft tube– Average flame temperature ~ 1900°F– Average flame heat flux ~ 15 BTU/ft2s

• The NexGen burner uses compressed air and fuel to supply the burner, whereas the Park DPL 3400 uses an electric motor to spin a blower fan and mechanical fuel pump

– Air Flow Metering:• Park uses a butterfly throttle valve• NexGen uses a sonic orifice

– Fuel Pressure• Park uses pressure regulator on pump• NexGen uses fuel tank head pressure

• Major advantages of a NexGen burner:– Precise metering of inlet parameters– Can be constructed in-house with easily obtainable

materials– Can be easily modified for future upgrades (as a result

of FAATC research)

Park DPL 3400

NexGen Burner

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NexGen Drawings

• Drawings are available online athttp://www.fire.tc.faa.gov/pdf/materials/NexGenPlans.pdf

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Remanufactured Stators and Turbulators

• MarlinEngineering, Inc was able to digitize the original stator and turbulator

• Irregularities were corrected in design software, symmetry was restored to design

• A computer numerical controlled (CNC) mill was used to cut new, corrected stators and turbulators

• The new prototypes were sent to the FAA Tech Center for evaluation and comparison with a properly configured NexGen burner

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Original Turbulator Prototype Turbulator

Front View

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Rear View

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Original Modified StatorPrototype Stator

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Comparison Tests• Datum:

– FAA NexGen 2 burner– Constructed as per FAA NexGen burner guidelines (

http://www.fire.tc.faa.gov/pdf/materials/NexGenPlans.pdf)• A new draft tube was made to fit the precise 4” round stator

– Original 4” i.d. pipe is not perfectly round– Stator could have been cut, but then we would have 2 imperfect parts– Tube was honed out to precisely fit the new stator– In the future, extruded tube with tight tolerance may be necessary for re-

engineered CNC stators

Burnthrough Update



Flame Temperature Measurements

1841

1929

1874

1943

1932

1909 19

13

1805

1885

1838

1873

1836

1938

1867

1805

1870

1851

1844

1875

1920

1863

1886

1933

1884

1700

1750

1800

1850

1900

1950

2000

1 2 3 4 5 6 7 AVG

Thermocouple

Te

mp

era

ture

, F

DATUM (OldParts)

NEW TURB &DRAFT TUBE

NEW STATORTURB DRAFTTUBE

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Comparison Tests

• Testing was performed on the picture frame sample holder with polyacrylonitrile (PAN) materials of 2 densities

• Samples were kept in conditioning chamber until testing

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Picture Frame BT Times

199 194 195

247240 243

0

50

100

150

200

250

300

DATUM (Old Parts) NEW TURB & DRAFT TUBE NEW STATOR TURB DRAFTTUBE

Burner Configuration

BT

Tim

e,

sec

8579

8611

Average of 4 Tests

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Results

• The new stator and turbulator had no significant effect on overall flame temperature or burnthrough times of PAN materials

• These new parts could be considered equivalent to the Monarch H215 stator and F124 turbulator

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NexGen, Burnthrough, and PIV Task Group

• Discuss plans, construction of burner with those interested in building a burner

• Discuss remanufactured stator and turbulator

• NexGen burner for other tests (seat cushion, cargo liner, powerplants)

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Questions?

Contact:

Robert Ochs

DOT/FAA Tech Center

BLDG 287

Atlantic City Int’l Airport

NJ 08405

[email protected]

1 609 485 4651

Federal Aviation Administration NexGen Burner Update International Aircraft Materials Fire Test...

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