Lockheed Martin Process Equivalency Test Plan For Hexcel 8552 IM7 Unidirectional Prepreg at 190 gsm & 35% RC

Transcription

1 Material Supplier Contact: Steve Ellery Marketing Manager, Americas Matrix Hexcel Corporation Tel: (801) Fax: (801) Lockheed Martin Contact: Rich Coulter, (661) Sunny Clarkson, Lockheed Martin Aeronautics 1011 Lockheed Way Palmdale, CA Document No.: NTP 1828E9 Lockheed Martin Process Equivalency Test Plan For Hexcel 8552 IM7 Unidirectional Prepreg at 190 gsm & 35% RC FAA Special Project Number SP4614WI-Q Prepared by: Yeow Ng, John Tomblin, Ric Abbott Reviewed by: John Adelmann, Kit Bowman, Bret Brummer (Raytheon Aircraft), Allison Crockett (General Atomics), Susan Daggett (ATK), Jim Diepenbrock, Rich Fields, Warren Hatfield (Raytheon Aircraft), Jeff Hendrix, Ed Hooper, Robert Glenn (Gulfstream), Dana Granville (U.S. Army), Erkan Kececi (Cessna), Jim Krone (Cessna), Guillermo Mayorga, William McCarvill (Commercial Chemistries), Mark Ofsthun (Spirit AeroSystems), David Ostrodka (FAA), Glen Otzinger (Toyota Aircraft), Dusty Penn (ACG), Chris Ridgard (ACG), Carl Rousseau (Lockheed Martin Aero), Engin Sabuncu (Cessna), Peter Shyprykevich (FAA), Mario Simard (Bombardier), Brent Stevenson (Texas Composite), Kristin Strole (NCAMP), Melanie Violette (Raytheon Aircraft), Stephen Ward (SW Composites), Bill Webb (Cytec), Cytec Engineered Materials, Hexcel Corporation, Spirit AeroSystems. Approved by: Page 1 of 21

2 TABLE OF CONTENTS 1. INTRODUCTION TEST METHODS PANEL AND SPECIMEN IDENTIFICATION UNCURED PREPREG AND RESIN TESTING CURED LAMINATE PHYSICAL TESTING CURED LAMINA AND LAMINATE MECHANICAL PROPERTY TESTING ENVIRONMENTAL CONDITIONING NON-AMBIENT TESTING PROCESS DEFINITION OTHER TEST PROCEDURES TACK TEST (REF. CESSNA AIRCRAFT COMPANY SPECIFICATION CPTI003): DRAPE TEST NOMINAL CURED PLY THICKNESS AND NORMALIZATION MECHANICAL TESTING INSPECTION, CONFORMANCE, WITNESSING, AND SHIPPING DATA REDUCTION AND REPORTING SPECIFICATIONS REFERENCES REVISIONS...15 APPENDIX APPENDIX APPENDIX Page 2 of 21

3 ABBREVIATIONS AND ACRONYMS ACO AMS ANOVA ASAP ASME ASTM BMI CLC CMH-17 CPT CTD CV DAR DER DMA DMIR DoD DSC ETD ETW FAA FAW FTIR FV HPLC IAB IR ILT MIDO NASA NCAMP NDI NIAR NIST OEM PCD QA QC QI RH RTD SACMA SAE SBS Aircraft Certification Office Aerospace Material Specification ANalysis Of VAriance Agate Statistical Analysis Program American Society of Mechanical Engineers American Society for Testing and Materials Bismaleimide Combined Loading Compression Composite Materials Handbook 17 (formerly MIL-HDBK-17) Cured Ply Thickness Cold Temperature Dry Coefficient of Variation Designated Airworthiness Representative Designated Engineering Representative Dynamic Mechanical Analysis Designated Manufacturing Inspection Representative Department of Defense Differential Scanning Calorimetry Elevated Temperature Dry Elevated Temperature Wet Federal Aviation Administration Fiber Areal Weight Fourier Transform Infrared Spectroscopy Fiber Volume fraction High Performance Liquid Chromatography Industry Advisory Board (an NCAMP Board) Infrared spectroscopy Inter-Laminar Tension Manufacturing Inspection District Office National Aeronautics and Space Administration National Center for Advanced Materials Performance Non-Destructive Inspection National Institute for Aviation Research National Institute of Standards and Technology Original Equipment Manufacturer Process Control Document Quality Assurance Quality Control Quasi-Isotropic Relative Humidity Room Temperature Dry Suppliers of Advanced Composite Materials Association Society of Automotive Engineers Short Beam Strength Page 3 of 21

4 Tg TGA WSU Glass Transition Temperature Thermogravimetric Analyzer Wichita State University 1. Introduction This document is a process equivalency test plan for Hexcel 8552 IM7 unidirectional prepreg, procured to NCAMP specification NMS 128/2. Panels using one batch of material will be fabricated by Lockheed Martin per NCAMP process specification NPS using baseline M cure cycle. The one batch material is intended for process equivalency purposes, where its test results will be statistically compared with those obtained from NTP 1828Q1 three batch material qualification. The purpose is to demonstrate that Lockheed Martin is capable of processing the material and producing test panels with properties equivalent to those of the original qualification. More information about this process equivalency and its limitations can be found in Section 6 of DOT/FAA/AR-03/19 and Section of MIL-HDBK-17-1F. If deemed appropriate, the equivalency data may be pooled with the qualification data to create a larger dataset. The data generated under this program is intended for general distribution to the public, either freely or at a price that does not exceed the cost of reproduction (e.g. printing) and distribution (e.g. postage). Data subjected to export control regulations, if any, will be made available on a case by case basis through written request to NCAMP. The following product forms will be used: Prepreg Name Hexcel 8552 IM7 unidirectional Description About the Prepreg Resin name: Hexcel 8552, Reinforcement: IM7 unidirectional, Sizing: 0.25% G, Fiber Areal Weight: 190 gsm, Resin Content: 35% The following material code will be used throughout this document to reference the prepreg: Material Code H12 Prepreg Name Hexcel 8552 IM7 unidirectional 2. Test Methods All testing will be in accordance with nationally recognized standards, methods and procedures. Specific mechanical property test methods applicable to the test program in this document include: ASTM D2344/D2344M-00(2006) Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their Laminates ASTM D3039/D3039M-00(2006) Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials Page 4 of 21

5 ASTM D3518/D3518M-94(2001) Standard Test Method for In-Plane Shear Response of Polymer Matrix Composite Materials by Tensile Test of a ± 45º Laminate In-Plane Shear Strength and Modulus ASTM D5766/D5766M-02a Standard Test Method for Open Hole Tensile Strength of Polymer Matrix Composite Laminates ASTM D5961/D5961M-05e1 Standard Test Method for Bearing Response of Polymer Matrix Composite Laminates ASTM D6484/D6484M-04 Standard Test Method for Open-Hole Compressive Strength of Polymer Matrix Composite Laminates ASTM D6641/D6641M-01e1 Standard Test Method for Determining the Compressive Properties of Polymer Matrix Composite Laminates Using a Combined Loading Compression (CLC) Test Fixture ASTM D7136/D7136M-05e1 Standard Test Method for Measuring the Damage Resistance of a Fiber-Reinforced Polymer Matrix Composite to a Drop-Weight Impact Event ASTM D7137/D7137M-05e1 Standard Test Method for Compressive Residual Strength Properties of Damaged Polymer Matrix Composite Plates Unless otherwise specified in this test plan or its related documentation, all recommendations of the standards shall be considered as mandatory. Any deviations from the standards must be approved by the FAA and documented in the final test report. Specific specimen preparation and test procedures should be identical to those used in the original qualification program NTP 1828Q1 and as documented in the PMC_Data_Collection_Template.xls of the qualification program. Unless otherwise specified, a tolerance of ±5 F will apply to all temperature conditions specified in this document. 3. Panel and Specimen Identification All panels and specimens shall be uniquely identified by a 11 code reference system, cross referenced with descriptive identification information as follows: This Document Number- Prepregger ID-Material Code-Fabricator ID-Intended Test Type-Batch ID-Cure Cycle ID- Test Panel ID-Actual Test Type-Test Condition-Specimen Number. For example, NTP1828E1-HXL-H12-RAC-WT-A-M1-2-FT-RTD-3] denotes Prepregger: Hexcel, Prepreg Name: Hexcel 8552 IM7 unidirectional, Fabricator: Raytheon Aircraft, Intended Test Type: Warp Tension, Prepreg Batch: A, Cure Cycle: Medium Temperature Cycle 1, Test Panel ID: 2, Actual Test Method: Fill Tension, Test Condition: Room Temperature Dry, and Specimen Number: 3. The testing lab may assign a separate identification code but must reference the 11 code reference system and uniquely identify the panels and specimens. Panels to be manufactured are listed in Appendix 2 and will follow the same I.D. above, inherently omitting the actual test type, test condition and specimen number. The above parameters can have the following values: Prepregger ID Page 5 of 21

6 Hexcel: HXL Material Code H12 Prepreg Name Hexcel 8552 IM7 unidirectional Fabricator ID (Company that layup, bag, and cure the test panels) Cytec: CYT Toray: TCA Nelcote: NCT Hexcel: HXL ACG: ACG TenCate: TEN Newport: NEW Boeing (Seattle): BAC Boeing (St. Louis): BPW Lockheed Martin Aeronautics: Gulfstream: GULF Cirrus Design Corporation: CIR LMA Israel Aircraft Industries: IAI Mitsubishi Heavy Industries: MHI Northrop Grumman: NGC Adam Aircraft: AAI GKN: GKN General Atomics: GAT Embraer: EBR Bell Helicopter: BEL Cessna: CES Sikorsky: SIK Bombardier: BBD AAR Composites: AAR Spirit Aerosystems: SPI Raytheon Aircraft: RAC New Piper Aircraft: NPA WSU/NIAR: WSU Liberty Aircraft: LIB ATK Space Systems : ATK Boeing (Philadelphia): BPH Texas Composites: TXC Goodrich: GR Bristol: BRI General Atomics: GAAS Intended Test Type WT: Warp tension UNT1, UNT2...: Un-notched Tension Layup 1, Layup 2, etc. FT: Fill Tension OHT1, OHT2...: Open Hole Tension Layup 1, Layup 2, etc. WC: Warp Compression OHC1, OHC2...: Open Hole Compression Layup 1 etc. FC: Fill Compression FHT1, FHT2 : Filled Hole Tension Layup 1, Layup 2 etc. IPS: In Plane Shear FHC1, FHC2 : Filled Hole Compression Layup 1, Layup 2 etc. SBS: Short Beam Strength SSB1, SSB2 : Single Shear Pin Bearing Layup 1, Layup 2..etc. LT: Longitudinal Tension CAI1: Compression After Impact Layup 1, Layup 2, etc. TT: Transverse Tension FSL: Freezer and Out Life Verification LC: Longitudinal Compression DMA: Dynamic Mechanical Analysis TC: Transverse Compression DSC: Differential Scanning Calorimetry ILT: Interlaminar Tension TGA: Thermogravimetric Analysis QI: Quasi Isotropic SBS1: Short Beam Strength Layup 1 (Note that the layup numbers 1, 2 and 3 correspond to those designated as quasi isotropic, soft and hard respectively). Batch ID: A, B, C, D, E, F etc. (corresponding prepreg batch numbers along with certificate of conformance will be included in the final report) Cure Cycle ID: (see NPS 81228) M1, M2, M3, etc.: Medium/Baseline Temp. Cure Cycle 1, 2, 3, etc. AH1, AH2, AH3, etc.: Alternate High Pressure Cure Cycle 1, 2, 3, etc. AL1, AL2, AL3, etc.: Alternate Low Pressure Cure Cycle 1, 2, 3, etc. Note: Cure Cycle numbers 1, 2, 3, etc. in Appendix 2 are for reference only. Actual numbers may vary depending on the actual cure cycle runs. Test Panel ID: 1,2,3,4,5,6,7,8,9,A,B,C.. etc. (restart from 1 for every Cure Cycle ID) WT: Warp tension FT: Fill Tension WC: Warp Compression FC: Fill Compression IPS: In Plane Shear Actual Test Type UNT1, UNT2...: Un-notched Tension Layup 1, Layup 2, etc. OHT1, OHT2...: Open Hole Tension Layup 1, Layup 2, etc. OHC1, OHC2...: Open Hole Compression Layup 1 etc. FHT1, FHT2 : Filled Hole Tension Layup 1, Layup 2 etc. FHC1, FHC2 : Filled Hole Compression Layup 1, Layup 2 etc. Page 6 of 21

7 SBS: Short Beam Strength PB1, PB2 : Single Shear Pin Bearing Layup 1, Layup 2..etc. LT: Longitudinal Tension CAI1: Compression After Impact Layup 1, Layup 2, etc. TT: Transverse Tension FSL: Freezer and Out Life Verification LC: Longitudinal Compression DMA: Dynamic Mechanical Analysis TC: Transverse Compression DSC: Differential Scanning Calorimetry ILT: Interlaminar Tension Layup TGA: Thermogravimetric Analysis QI: Quasi Isotropic SBS1: Short Beam Strength Layup 1 Test Condition: CTD, RTD, ETD, ETW (cold temp. dry moisture, room temp. dry moisture, etc., see section 6, if testing at more than one elevated temperature use ETD1, ETD2 etc.) D, W (dry, wet conditions for DMA) Specimen Number: 1,2,3,4,5,6,7,8,9,A,B,C.. etc. 4. Uncured Prepreg and Resin Testing Refer to the requirements in NMS 128/2. 5. Cured Laminate Physical Testing The properties in Table 1 shall be determined for each panel used for test coupons with the exception of Tg by DMA which will be conducted on one laminate per batch from each oven cure conducted where that batch is present. The tests will be performed by the National Institute for Aviation Research (NIAR) Composites Laboratory under the supervision of NCAMP. These tests may be repeated by the participating fabricator. Table 1 Property Condition/Method (Note 1) Min Replicates per panel All data from mechanical test specimens Cured Ply Thickness ASTM D Laminate Density ASTM D Fiber Volume, % by Volume ASTM D (Note 2) 3 Resin Content, % by Weight ASTM D (Note 2) 3 Ultrasonic Through Transmission, C-Scan Glass Transition Temperature, Tg MIL-HDBK-787A (Note 3) 1 Dry and Wet SACMA SRM 18R-94 (by DMA) or HSP-T2 Rev 1 (by TMA) (Note 5) 1 Dry, 1 Wet (Note 4) Notes 1: Where the applicable standard allows variations in specimen form or test method, the specific parameters to be used will be specified in the test work instructions and reported in the final test report. 2: Method II, except for laminates of materials where actual fiber weight is not known accurately prior to impregnation, as in the case for unidirectional materials. For these materials, to verify Method II is accurate, a minimum of 12 samples per batch shall be tested by Method I, Procedure B. Page 7 of 21

8 3: Five MHz is preferred for solid laminates. Panels with anomaly should be segregated. Microscopy images may be taken from questionable areas. NCAMP must be involved in the review of all the C-scans. 4: Minimum total of 8 dry and 8 wet. 5: HSP-T2 Revision 1 is a Hexcel non-proprietary test method standard which may be obtained from NCAMP. HSP-T2 is similar but not equivalent to ASTM E Cured Lamina and Laminate Mechanical Property Testing The following tests will be performed by the NIAR Composites Laboratory under the supervision of NCAMP. Specimen dimensions should be taken before moisture conditioning. Test environments are defined as: CTD = -65±5 F, dry RTD = 70±10 F, room temperature dry ETD = 250±5 F dry ETW = 250±5 F, wet (equilibrium moisture content) Elevated temperature level of 250±5 F may be reduced if wet glass transition temperature is not 300 F or higher. The elevated temperature level will be adjusted to 50 F below the measured wet glass transition temperature. All failure modes must be clearly identified. Testing shall achieve appropriate failure modes. Within each test method and test environment, the failure mode shall be evaluated immediately after each test by an FAA ACO engineer or FAA DER. Obvious improper failure modes shall be logged. If a second improper failure mode occurs, testing shall cease until the test setup and test data can be reviewed by the FAA and NCAMP. Retain the samples until data review is complete and the test report is finalized. All tested specimens shall be digitally photographed after each test in order to pictorially document failure modes. Representative photos shall be included in the final report. 6.1 Environmental Conditioning For dry testing, specimens will be dried at 160 F±5 F for 120 to 130 hours. After drying, specimens should be kept in a desiccator until mechanical testing. Alternatively, the specimens may be left at ambient laboratory condition for a maximum of 14 days until mechanical testing (no drying will be required if specimens are tested within 14 days from the date they were cured). Ambient laboratory condition is defined as 70 F±10 F. Since moisture absorption and desorption rate for epoxy is very slow at ambient temperature, there is no requirement to maintain relative humidity levels. For wet conditioning, specimens will be dried at 160 F±5 F for 120 to 130 hours before being conditioned to equilibrium at 160 F±5 F and 85% ± 5%. Effective moisture equilibrium is achieved when the average moisture content of the traveler specimen changes Page 8 of 21

9 by less than 0.05% for three consecutive readings which are 7 ±0.5 days apart and may be expressed by: W i -W W b i - 1 < where: W i = weight at current time W i 1 = weight at previous time W b = baseline weight prior to conditioning When representative specimens may not be measured to determine the moisture content (due to size, fastener and tab effects), traveler coupons of at least 1 by 1 by specimen thickness and weighing at least 5 grams may be used to establish weight gain measurements. If the specimens or traveler coupons pass the criteria for three consecutive readings which are 7 ±0.5 days apart, the specimens may be kept in the environmental chamber for up to an additional 60 days. Alternatively, the specimens may be removed from the environmental chamber and placed in a sealed plastic bag along with a moist cotton towel for a maximum of 14 days until mechanical testing. Strain-gaged specimens may be removed from the controlled environment for a maximum of 2 hours for application of gages in ambient laboratory conditions. 6.2 Non-ambient Testing The chamber should be of adequate size that all test fixtures and load frame grips may be contained within the chamber. For elevated temperature testing, the temperature chamber, test fixture, and grips should be preheated to the specified temperature. Each specimen should be heated to the required test temperature as verified by a thermocouple in direct contact with and taped to the specimen gage section. The heat-up time of the specimen shall not exceed 5 minutes. The test should start 2 + minutes after the specimen has reached the test temperature. During the test, the 1 0 temperature, as measured on the specimen, shall be within ±5 F of the required test temperature. For subzero temperature testing, each specimen should be cooled to the required test temperature as verified by a thermocouple in direct contact with and taped to the specimen gage section. The test should start 5 + minutes after the specimen has reached the test 1 0 temperature. During the test, the temperature, as measured on the specimen, shall be within ±5 F of the required test temperature. 6.3 Process Definition All panels will be fabricated in accordance with NCAMP Process Specification NPS Fabrication of NMS 128 Qualification, Equivalency, and Acceptance Test Panels. Page 9 of 21

10 The panel dimensions listed in appendix 2 are minima and refer to the size of the caul sheets. Larger panels may be manufactured. In order to facilitate individual specimen traceability, individual specimen numbering and/or skewed lines must be written or drawn across each sub-panel as shown in Figure Other Test Procedures Figure 1 Specimen Traceability Line 7.1 Tack Test (Ref. Cessna Aircraft Company Specification CPTI003): The purpose of this test method is to determine the level of prepreg tack through its ability to adhere to itself and to a vertical surface. Equipments needed are (1) A corrosion resistant steel plate with a commercial 2D finish and (2) A squeegee or 1-inch diameter by 1-inch wide roller. Procedure: 1. This tack test shall be performed at 70 F±10 F and 0-60% RH. Cut two 3-inch by 1-inch specimens from the prepreg. The 3-inch dimension shall be in the 0º or warp direction. 2. Attach one piece of the prepreg specimen to the plate with light pressure using a squeegee or roller. 3. Remove the backing and apply the next strip to the first one. Tack in a similar manner. Remove the backing from the second strip. 4. Position the plate vertically. 5. Determine the tack level as follows: a. Tack level I Low tack, prepreg is stiff and boardy b. Tack level II Dry but slight drape c. Tack level III - Slight tack sticks to itself but not to a vertical surface. Unable to adhere to the vertical tool surface for 30 minutes. d. Tack level IV - Good tack, prepreg sticks to itself and vertical tool. Adhered to the vertical tool surface for more than 30 minutes. Page 10 of 21

11 e. Tack level V Sticks to hands or gloves but no resin transfer. f. Tack level VI High tack, wet, and sloppy with resin transfer. 7.2 Drape Test The drape of the prepreg shall be determined at 70 F±10 F and 0-60% RH as follows: a. Cut sufficient material to obtain three specimens that are a minimum of 2-inches long by a minimum of 3-inches wide, and remove any release paper or film. b. Complete wrapping each specimen separately over a 0.25 inch diameter mandrel within 15 seconds of initiation, with fiber direction transverse to mandrel centerline. c. Remove each specimen from the mandrel and inspect for evidence of cracks, wrinkles, folds, or tears on the surface of the material. Evidence of these defects in cut edges extending less than 0.13 inch inward maximum from the edge shall not be considered rejectable. If no evidence of filament breakage can be visually observed, the specimen has met the requirements for drape. Report as pass or fail. 8. Nominal Cured Ply Thickness and Normalization The nominal cured ply thickness and/or fiber volume fraction obtained in NTP 1828Q1 will be used. Most lamina level tension and compression strength and modulus properties, and all laminate level properties will be normalized according to fiber volume fraction. Lamina level properties that will not be normalized include 90º tensile strength and modulus (unidirectional only), 90º compressive strength and modulus (unidirectional only), in-plane shear strength and modulus, Poisson s ratio, and SBS. After normalizing, data scatter should reduce or remain the same. If data scatter increases significantly after normalizing, the reason should be investigated. Wherever properties are normalized, both measured and normalized data will be reported. In cases where the fabric areal weight can be shown to be very close to nominal, normalization by cured ply thickness (CPT) may be used, i.e.: Normalized Value = Measured Value x Measured CPT / Nominal CPT 9. Mechanical Testing A single batch of prepreg will be used to demonstrate equivalency. As in the original database tests, each property/test condition will require two separate cure cycles as shown in Figure 2. Table 2 shows the single batch equivalency test matrix. The layup angles 0º, 45º, - 45º, and 90º refer to the orientation of the fiber direction. The number of plies is chosen to produce a laminate thickness appropriate for the test method in question. This is also called out in appendices 1 and 2. These single batch tests are designed to demonstrate equivalency with the three batch data for purposes described in MIL-HDBK-17-1F Section and DOT/FAA/AR-03/19 Section 6. Specifically, equivalency demonstration may allow the panel manufacturer to utilize the common database of material properties and basis values. Page 11 of 21

12 For each property and test condition, the statistical test methods of reference 2 will be used to analyze the data. Material Batch BATCH 1 Panel Manufacturing & Independent Cure Process PANEL 1 PANEL 2 Number of Specimens Required per Test Method & Environment 4 spec. 4 spec. 8 SPECIMENS TOTAL Figure 2 Specimen Selection Methodology and Processing Traceability per Test Method and Environmental Condition Used to Establish Material Equivalence. Page 12 of 21

13 Table 2 Mechanical Test Matrix Layup Test Type and Direction Property Number of Batches x Number of Panels x Number of Test Specimens Test Temperature/Moisture Condition CTD RTD ETD ETW [0] 6 ASTM D Tension Modulus 1x2x4 1x2x4 1x2x4 ASTM D [0] 14 Modulus 1x2x4 1x2x4 1x2x4 Compression (Note 1) [0/90] 2S ASTM D Tension Strength + Modulus 1x2x4 1x2x4 1x2x4 ASTM D [90/0/90] 5 Strength + Modulus 1x2x4 1x2x4 1x2x4 Compression (Note 1) ASTM D3518 In-Plane [45/-45] 3S Strength + Modulus 1x2x4 1x2x4 1x2x4 Shear ASTM D2344 Short Beam [0] 34 Strength 1x2x4 1x2x4 Strength (25/50/25 - QI) ASTM D5766 Open Hole Strength 1x2x4 1x2x4 1x2x4 [45/0/-45/90] 2S Tension (25/50/25 - QI) ASTM D6484 Open Hole Strength 1x2x4 1x2x4 [45/0/-45/90] 3S Compression (Note 1) (25/50/25 - QI) [45/0/-45/90] 3S ASTM D7136 & D7137 Compression after impact 1500 in-lbs/in (Note 1) Strength 1x1x6 Note 1: Back-to-back strain gages needed on the first specimen of each environment. If no buckling is observed, the remaining modulus specimens will require strain gage on one side of the specimens only. Appropriate extensometer may be used in place of the strain gage. 10. Inspection, Conformance, Witnessing, and Shipping The 1-batch equivalency panels should be fabricated according to the process definition in section 6.3. Minor deviations from the process definition may be allowed but must be approved by the FAA prior to panel fabrication. At minimum, the following panel information should be conformed by the FAA: 1. Process control data such as temperature, pressure, and vacuum as required by section Panel identification and labeling per section 3, section 6.3, and appendix 2. Stacking sequence may not be verified on cured panel level unless staggered tabs were cut into the prepregs prior to layup. The above FAA conformity will be performed at the panel fabricator site before the panels are sent to NCAMP. The panel conformity must be performed by FAA MIDO inspectors at the request of FAA ACO engineers. The MIDO inspector may elect to delegate this responsibility to a DMIR or DAR. Prior to shipping the panels, verify the following: 1. The appropriate sections in the Panel Data sheet of PMC_Data_Collection_Template.xls file has been completed. Page 13 of 21

14 2. In-process monitoring data such as part temperature, autoclave temperature, autoclave pressure, autoclave vacuum, and part vacuum readings, preferably in electronic format, is included 3. FAA conformity record (if needed), is included. 4. The panel names match the names listed in Appendix 2 of the test plan Send the panels along with the in-process monitoring data and FAA conformity records to: Wichita State University NIAR NCAMP, Attn: Yeow Ng 1845 Fairmount Ave. Wichita, KS USA Tel: Prior to testing, test specimen conformity must be performed by MIDO inspectors at the request of ACO engineers. The MIDO inspector may elect to delegate this responsibility to a DMIR or DAR. Testing must be witnessed by the FAA (except for those in section 4). Witnessing can be performed by ACO engineers, or they may delegate this responsibility to a DER, MIDO inspector, DMIR or DAR. Mechanical testing will be carried out at the National Institute for Aviation Research, Wichita State University. The test setup and procedures in section 4 will be reviewed by NCAMP IAB and NCAMP staff during facility audit. 11. Data Reduction and Reporting The data generated in this test plan will be statistically compared with the data generated from the original qualification program (NTP 1828Q1) using the methodology of reference 2. Both the actual Coefficient of Variation (CV) and modified CV will be used in the statistical tests. The modified CV will be calculated as follows: 1) If the measured CV at a given test condition is 0% to 4%, use an assumed CV of 6% or the pooled CV, whichever is greater. 2) If the measured CV at a given test condition is between 4% and 8%, use an assumed CV = 0.5*(measured individual CV) + 4% or the pooled CV, whichever is greater. 3) If the measured CV at a given test condition is 8% to 10%, use the measured CV or the pooled CV, whichever is greater. 4) If the measured CV at a given test condition is 10% or greater, question the data. And for setting specification requirement use a maximum CV of 10%. If deemed appropriate, the single batch equivalency data may be pooled into the three batch qualification data to generate material properties that are more representative of the overall material performance. Page 14 of 21

15 12. Specifications All materials will be manufactured to Hexcel prepreg Process Control Document PCD- NMS128 latest revision using the nominal parameters given in section 1 above, and in accordance with NMS 128/ References Reference 1. DOT/FAA/AR-02/109 Recommended criteria and Guidelines for the Development of a Material Specification for Carbon/Epoxy Prepregs to be used on FAA Certified Structures. Reference 2. DOT/FAA/AR-03/19 Material Qualification and Equivalency for Polymer Matrix Composite Material Systems. Reference 3. MIL-HDBK-17 Rev. F, Composite Materials Handbook Reference 4. DOT/FAA/AR-02/110 Recommendations and Guidelines for the Development of a Process Specification for the Fabrication of Carbon Fiber Reinforced Epoxy Composite Structures. 14. Revisions Revision Date Description - 2/5/2007 Initial Release A 6/7/2007 Added panel shipping information to section 10 Updated ASTM test method revisions in multiple sections. Page 15 of 21

16 Appendix 1 Hexcel 8552 IM7 Unidirectional Prepreg Equivalency Tests Prepreg Batch 190 gsm Unidirectional Orientation Cond. A B C Cure Cycle Property M1 M2 M1 M2 M1 M2 Longitudinal Tensile Properties (100/0/0) CTD 4 4 Strength & Modulus (extensometer OR CEA UT-350 OR CEA-XX-250UW-350) [0]6 RTD 4 4 ASTM D 3039 ETD 0.50 x (0 ) in. (tabs required) ETW 4 4 Longitudinal Compression Properties (100/0/0) CTD Modulus (extensometer OR CEA-XX-125UT-350) [0]14 RTD 4 4 ASTM D 6641 ETD x 5.50 (0 ) in. ETW 4 4 Unnotched Tensile Properties 0 (50/0/50) CTD 4 4 Strength & Modulus (extensometer OR CEA-XX-250UW-350) [0/90]2S RTD 4 4 ASTM D 3039 ETD 1.00 x (0 ) in. (tabs optional) ETW 4 4 Unnotched Compression Properties 0 (33/0/67) CTD Strength & Modulus (extensometer OR CEA-XX-125UT-350) [90/ 0/90]5 RTD 4 4 ASTM D 6641 ETD x 5.50 (0 ) in. ETW 4 4 In-Plane Shear Properties (0/100/0) CTD 4 4 Strength & Modulus (extensometer OR one CEA UT-350 OR two CEA-XX- [45/-45]3S RTD UW-350) Page 16 of 21

17 ASTM D 3518 ETD 1.00 x (0 ) in. (tabs optional) ETW 4 4 Short Beam Strength Properties (100/0/0) CTD Strength [ 0]34 RTD 4 4 ASTM D 2344 ETD 0.50 x 1.50 (0 ) in. ETW 4 4 Open Hole Tension Properties 1 (25/50/25 - QI) CTD 4 4 Strength [45/0/-45/90]2S RTD 4 4 ASTM D 5766 ETD 1.5 x 12.0 (0 ) in., 0.25 in. dia hole ETW 4 4 Open Hole Compression Properties 1 (25/50/25 - QI) CTD Strength [45/0/-45/90]3S RTD 4 4 ASTM D 6484 ETD 1.5 x 12.0 (0 ) in., 0.25 in. dia hole ETW 4 4 Compression Strength after Impact 1 (25/50/25 - QI) CTD Strength [45/0/-45/90]3S RTD 6 ASTM D7136 & D7137 ETD 4.0 x 6.0 (0 ) in. ETW 1500 in-lb/in Page 17 of 21

18 Appendix 2 Hexcel 8552 IM7 Unidirectional Prepreg Equivalency Panels 190 gsm carbon uni CPT= " approx Length Width # Panel ID Table Batch (%0/%±45/%90) Layup Plies Qty inch direction inch direction NTP1828E9-HXL-H12-LMA- LT-A-M1-1 2 A (100/0/0) [0] along 90º 24 along 0º NTP1828E9-HXL-H12-LMA- LT-A-M2-1 2 A (100/0/0) [0] along 90º 24 along 0º NTP1828E9-HXL-H12-LMA- LC-A-M1-1 2 A (100/0/0) [0] along 90º 13 along 0º NTP1828E9-HXL-H12-LMA- LC-A-M2-1 2 A (100/0/0) [0] along 90º 13 along 0º NTP1828E9-HXL-H12-LMA- UNT0-A-M1-1 2 A (50/0/50) [0/90]2S along 90º 24 along 0º NTP1828E9-HXL-H12-LMA- UNT0-A-M2-1 2 A (50/0/50) [0/90]2S along 90º 24 along 0º NTP1828E9-HXL-H12-LMA- UNC0-A-M1-1 2 A (33/0/67) [90/0/90] along 90º 13 along 0º NTP1828E9-HXL-H12-LMA- UNC0-A-M2-1 2 A (33/0/67) [90/0/90] along 90º 13 along 0º NTP1828E9-HXL-H12-LMA- IPS-A-M1-1 2 A (0/100/0) [45/-45]3S any 24 any NTP1828E9-HXL-H12-LMA- IPS-A-M2-1 2 A (0/100/0) [45/-45]3S any 24 any NTP1828E9-HXL-H12-LMA- SBS-A-M1-1 2 A (100/0/0) [0] along 90º 8 along 0º NTP1828E9-HXL-H12-LMA- SBS-A-M2-1 2 A (100/0/0) [0] along 90º 8 along 0º NTP1828E9-HXL-H12-LMA- OHT1-A-M1-1 2 A ( 25/50/25 - QI) [45/0/-45/90]2S along 90º 28 along 0º NTP1828E9-HXL-H12-LMA- OHT1-A-M2-1 2 A ( 25/50/25 - QI) [45/0/-45/90]2S along 90º 28 along 0º NTP1828E9-HXL-H12-LMA- OHC1-A-M1-1 2 A ( 25/50/25 - QI) [45/0/-45/90]3S along 90º 28 along 0º NTP1828E9-HXL-H12-LMA- OHC1-A-M2-1 2 A ( 25/50/25 - QI) [45/0/-45/90]3S along 90º 28 along 0º NTP1828E9-HXL-H12-LMA- CAI1-A-M1-1 2 A ( 25/50/25 - QI) [45/0/-45/90]3S along 90º 28 along 0º Page 18 of 21

19 Appendix 3 (Below are sample pictures from NCAMP s PMC_Data_Collection_Template.xls. Please use the actual templates to record the information) General Material Description (To be completed by the material supplier) COMPOSITE MATERIAL DATA COLLECTION TEMPLATE GENERAL MATERIAL DESCRIPTION TO BE COMPLETED BY MATERIAL SUPPLIER ASTM E1434 Item No. Required Entry Required Entry if Applicable Optional COMPOSITE Composite Common Name Composite Source (Supplier and/or supplier location) Composite Product Name (Supplier's catalog name) Composite Material Form General Reinforcement Form or Fabric Weave Style Nominal Fiber Areal Weight (of tape, fabric, or preform) g/m 2 Nominal Resin Solids Content (of prepreg) wt. % Composite Specification Number Composite Specification Dash Number Scrim Material Common Name Unit or Format < select from pull-down < select from pull-down Scrim Weave Style < select from pull-down Scrim Source (Supplier) Nominal Cured Ply Thickness Related to I9 inch MATRIX Matrix Type < select from pull-down Matrix Common Name Matrix Source (Supplier) Matrix Nominal Density (cured) g/cm 3 Matrix Specification Number REINFORCEMENT Fiber Type < select from pull-down Fiber Common Name Fiber Source Fiber Nominal Density g/cm 3 Fiber Length (for discontinuous reinforcement) inch Tow Twist (0 = no twist) turns/inch Fiber Surface Treatment (Yes or No) < select from pull-down Fiber Sizing/Finish Type Fiber Sizing/Finish Name Sizing/Finish Content, Nominal wt. % Filament Count per Tow ##k Tow Denier denier Nominal Tow Yield (forms used as tow) linear ft./lb. Fiber Specification Number PREFORM (Including Fabrics) Preform Source (Weaver, Braider, or Stitcher) Tackifier Type Tackifier Common Name Tackifier Source Yarn Count, Nominal (Warp x Fill for Fabrics) Stitching Count Stitching Yarn Row Spacing Preform Specification Number Tackifier Specification Number yarns/inch stitches/inch inch NOTES Material Description Note or Comment Page 19 of 21

20 Material Batch Information (To be completed by the material supplier) COMPOSITE MATERIAL DATA COLLECTION TEMPLATE SPECIFIC BATCH INFORMATION TO BE COMPLETED BY MATERIAL SUPPLIER Required Entry Required Entry if Applicable Optional ASTM E1434 PREPREG Item No. Batch 1 Batch 2 Batch 3 Batch 4 Batch 5 Unit or Format Composite Material (Prepreg) Batch Number (assign number for liquid molding) Composite Batch Date of Manufacture mm/dd/yyyy Batch Average Fiber Areal Weight g/m 2 Batch Average Resin (solids) Content (of prepreg) wt. % Batch Avg. Volatile Content (of prepreg or RTM resin) wt. % Volatile Test Temperature F Batch Average Flow (of prepreg) wt. % Flow Test Temperature F Flow Test Pressure psi Batch Average Gel Time (of RTM or prepreg resin) minutes Gel Test Temperature F Tack (Low, Medium, or High for prepreg) Drape (Low, Medium, or High for prepreg) MATRIX Matrix Lot or Batch Number Matrix Lot Date of Manufacture mm/dd/yyyy Matrix Density, Lot Average g/cm 3 REINFORCEMENT 0 (Warp) Direction Fibers Fiber Lot Number(s) Fiber Lot Date of Manufacture mm/dd/yyyy Fiber Lot Avg. Density g/cm 3 Fiber Lot Avg. Tensile Strength ksi Fiber Lot Avg. Tensile Modulus Msi 90 (Fill) Direction Fibers Fiber Lot Number(s) Fiber Lot Date of Manufacture mm/dd/yyyy Fiber Lot Avg. Density g/cm 3 Fiber Lot Avg. Tensile Strength ksi Fiber Lot Avg. Tensile Modulus Msi Through Thickness Direction Fibers Fiber Lot Number(s) Fiber Lot Date of Manufacture mm/dd/yyyy Fiber Lot Avg. Density g/cm 3 Fiber Lot Avg. Tensile Strength ksi Fiber Lot Avg. Tensile Modulus Msi Bias (θ ) Direction Fibers Fiber Lot Number(s) Fiber Lot Date of Manufacture mm/dd/yyyy Fiber Lot Avg. Density g/cm 3 Fiber Lot Avg. Tensile Strength ksi Fiber Lot Avg. Tensile Modulus Msi Stitching Fibers Fiber Lot Number(s) Fiber Lot Date of Manufacture mm/dd/yyyy Fiber Lot Avg. Density g/cm 3 Fiber Lot Avg. Tensile Strength ksi Fiber Lot Avg. Tensile Modulus Msi PREFORM (Including Fabrics) Preform or Fabric Lot Number (e.g.: weaver lot number) Preform or Fabric Date of Manufacture mm/dd/yyyy Tackifier Lot Number Tackifier Lot Date of Manufacture mm/dd/yyyy Tackifier Content wt. % NOTES Batch Information Note or Comment Page 20 of 21

21 Test Panel Data (To be completed by the panel fabricator) COMPOSITE MATERIAL DATA COLLECTION TEMPLATE TEST PANEL (OR SUB-PANEL) DATA Subpanels must be identified to indicate the parent panel Required Entry Required Entry if Applicable If Applicable to All Panels on this Sheet, Enter for Panel 1 Only and Check Here ASTM E1434 PANEL DESCRIPTION (TO BE COMPLETED BY PANEL FABRICATOR) Unit or Format Item No. Panel 1 Panel 2 Panel 3 Pane Panel or Sub-panel Identification Number (used for the consolidated and fully processed panel) Panel Description (type of test for which the panel is to be used) Panel Fabricator Composite Material Batch Number Number of Layers (plies) I7 Layup Stacking Sequence CMH-17 format Related to H7 Composite Material Lot Number (subset of batch) Composite Material Roll Number PANEL PROCESSING (TO BE COMPLETED BY PANEL FABRICATOR) Lay-up Method select from pull-down > Type of curing or final consolidation process select from pull-down > Autoclave, Oven, or Press ID Heating Rate to Cure Temperature F/minute Cure Temperature F Cure Pressure (enter 0 for vacuum only) psig Cure Time minutes Cure Vacuum Maintained Throughout Cure? No or Yes Cooling Rate After Cure F/minute Panel Removal Tool Temperature F Cure Vacuum Vent Pressure psig Postcure Temperature F Postcure Time minutes RTM Vacuum Used? (Yes or No) No or Yes RTM/VARTM Resin Temperature at Injection F RTM/VARTM Preform Degas Procedure Text or Reference RTM/VARTM Preform Temperature at Insertion F RTM/VARTM Tool Temperature Prior to Injection F RTM/VARTM Resin Injection Rate lb./min. or ml/min. Optional Test Panel Data, continued (To be completed by the testing lab) SECONDARY PANEL OPERATIONS (TO BE COMPLETED BY TESTING LAB) Bonded Tab (doubler) Material I48 Bonded Tab (doubler) Layup (stacking sequence) CMH-17 format I50 Bonded Tab (doubler) Nominal Thickness inch I51 Bonded Tab (doubler) Bevel Angle degrees I52 Bonded Tab (doubler) Nominal Length inch I53 Bonded Tab (doubler) Bonding Adhesive I49 Bonded Tab (doubler) Bond Cycle Temperature F I54 Bonded Tab (doubler) Bond Cycle Time minutes I55 Bonded Tab (doubler) Bond Cycle Pressure psi Type of Equipment Used for Bonding Tabs select from pull-down > Are Tabs Bonded to Individual Specimens or to Entire Panel? select from pull-down > Sandwich Panel Core Common Name I26 Sandwich Panel Core Material Type select from pull-down > I27 Sandwich Panel Core Material I28 Sandwich Panel Core Material Manufacturer I29 Sandwich Panel Core Material Lot Number I30 Nominal Sandwich Core Cell Size (for honeycomb hexcore) inch I31 Nominal Sandwich Core Cell Count (for honeycomb OX or flexible core) cells per inch I31 Nominal Sandwich Core Density lb./ft. 3 I32 Nominal Sandwich Core Thickness inch Non-test Sandwich Face Material Non-test Sandwich Face Nominal Thickness inch Sandwich Bonding Adhesive Common Name I34 Sandwich Bonding Adhesive Manufacturer I36 Sandwich Bonding Adhesive Lot Number I37 Sandwich Bonding Adhesive Date of Manufacture mm/dd/yyyy I38 Sandwich Secondary Bond Cycle Time/Temp./Pressure PANEL PROPERTIES (Prior to Secondary Operations) (TO BE COMPLETED BY TESTING LAB) Panel Thickness (panel average) inch Panel Density g/cm 3 Panel Density Test Method Panel Fiber Volume (panel average) vol.% M7 Panel Fiber Volume Test Method Panel Dry Glass Transition Temperature F Panel Wet Glass Transition Temperature F Panel Glass Transition Test Method Panel Void Content vol.% Panel Void Content Test Method NOTES Panel Data Note or Comment Additional reporting requirements are related to testing procedures and are to be completed by the testing labs. The templates may be found in NCAMP s PMC_Data_Collection_Template.xls Page 21 of 21