Advanced General Aviation Transport Experiments

Transcription

1 Advanced General Aviation Transport Experiments B Basis Design Allowables for Epoxy Based Prepreg Fiberite Plain Weave Graphite Fabric T65 K-7-PW / 774 AGATE-WP.-5- September J. Tomblin, J. McKenna, Y. Ng, K. S. Raju National Institute for Aviation Research Wichita State University Wichita, KS 676-9

2 TABLE OF CONTENTS. INTRODUCTION...5. Scope Symbols Used Acronyms and Definitions References Methodology Test Matrix Environmental Conditioning Fluid Sensitivity Screening Normalization Procedures Statistical Analysis Material Performance Envelope and Interpolation Interpolation Example FIBERITE T65 K-7-PW / 774 PREPREG PROPERTIES...7. Prepreg Documentation by Prepreg Lot Process Specification FIBERITE T65 K-7-PW / 774 LAMINATE PROPERTIES.... Test Results..... Summary..... Individual Test Summaries Tension, -axis Tension, -axis Compression, -axis Compression, -axis Shear, axis Shear, axis Individual Test Charts Tension, -axis Tension, -axis Compression, -axis Compression, -axis Shear, axis Shear, axis Raw Data... 7

3 .. Raw Data Spreadsheets and Scatter Charts Fluid Sensitivity Raw Data Spreadsheets and Scatter Charts Representative Shear Stress-Strain Curve Statistical Results Plot by Condition Plot of Pooled Data....4 Moisture Conditioning History Charts....5 Physical Test Results TESTING AND REPORTING COMMENTS...8 APPENDIX A. PHYSICAL TEST DATA SUPPLIED BY MATERIAL VENDOR... APPENDIX B. DATES OF PANEL MANUFACTURE AND COPY OF FAA FORM

4 . INTRODUCTION. Scope The test methods and results described in this document are intended to provide basic composite properties essential to most methods of analysis. These properties are considered to provide the initial base of the building block approach. Additional coupon level tests and subelement tests may be required to fully substantiate the full-scale design. The test methods and results contained in this document are consistent with MIL- HDBK-7-E,D,E - Military Handbook for Polymer Matrix Composites. All material, specimens, fixtures and test results contained within this document were traceable and conformed by the Federal Aviation Administration (FAA). It should be noted that before application of the basis values presented in this document to design, demonstration of the ability to consistently produce equivalent material properties as that evaluated during this program should be substantiated through an acceptable test program. 5

5 . Symbols Used tu c E t E c E t E su F su F cu F tu F cu F tu F s G major Poisson s ratio, tension micro-strain compressive modulus, longitudinal tensile modulus, longitudinal compressive modulus, transverse tensile modulus, transverse in plane shear strength apparent interlaminar shear strength compressive strength, longitudinal tensile strength, longitudinal compressive strength, transverse tensile strength, transverse in plane shear modulus Superscripts c cu s su t tu compression compression ultimate shear shear ultimate tension tension ultimate Subscripts axis; longitudinal (parallel to warp direction of reinforcement) axis; transverse (parallel to fill direction of reinforcement) in plane shear interlaminar shear (apparent) 6

6 . Acronyms and Definitions A Basis 95% lower confidence limit on the first population percentile AGATE Advanced General Aviation Transport Experiments ASTM American Society for Testing and Materials B Basis 95% lower confidence limit on the tenth population percentile C. V. coefficient of variation CTD cold temperature dry CPT cured ply thickness DMA dynamic mechanical analysis dry specimen tested with an as fabricated moisture content ETD elevated temperature dry ETW elevated temperature wet FAR Federal Aviation Regulations FAW fiber areal weight Gr/Ep Graphite/Epoxy NASA National Aeronautics and Space Administration RTD room temperature dry SACMA Suppliers of Advanced Composite Materials Association SRM SACMA Recommended Method T g glass transition temperature t ply cured ply thickness wet specimen tested with an equilibrium moisture content per section.5. 7

7 .4 References ASTM Standards D9-95 Tensile Properties of Polymer Matrix Composite Materials D579-9 Shear Properties of Composite Materials by the V-Notched Beam Method D44-89 Apparent Interlaminar Shear Strength of Parallel Fiber Composites by Short Beam Method D79-9 Density and Specific Gravity (Relative Density) of Plastics by Displacement D74-94 Void Content of Reinforced Plastics D7-9 Fiber Content of Resin Matrix Composites by Matrix Digestion D695-9 Compressive Properties of Rigid Plastics SACMA Standards SRM -94 SRM 8-94 SRM 8-94 Compressive Properties of Oriented Fiber-Resin Composites Short Beam Shear Strength of Oriented Fiber-Resin Composites Glass Transition Temperature (T g ) Determination by DMA of Oriented Fiber-Resin Composites Other Documents FAA Document DOT/FAA/AR-/47: Material Qualification and Equivalency for Polymer Matrix Composite Material Systems, J.S. Tomblin, Y.C. Ng and K.S. Raju,. MIL-HDBK-7 E, D, E Military Handbook for Polymer Matrix Composites Cessna Aircraft Company, Document # : B-Basis Design Allowables Test Plan for Preimpregnated Carbon/Epoxy Broadgoods, Revision B, January

8 .5 Methodology.5. Test Matrix Testing was performed according to the test methods delineated in the test matrix, with modifications as referenced in the AGATE report, Material Qualification and Equivalency for Polymer Matrix Composite Material Systems. The test matrix for properties included in this document is listed on the next page, with the following notation cited in each column: # x # where the first # represents the required number of prepreg batches, defined as: Prepreg containing T65 K-7-PW graphite fabric from one mill roll, impregnated with one batch of resin in one continuous manufacturing operation with traceability to all components. The second # represents the required number of replicates per prepreg batch. For example, x 6 refers to three prepreg batches of material and six specimens per prepreg batch for a total requirement of 8 test specimens. 9

9 Table.5.: Test Matrix and Standards Used TEST METHOD NO. OF REPLICATES PER TEST CONDITION CTD,5 RTD,5 ETW ETD 4,5 o (warp) Tension Strength ASTM D9-95 x4 x4 x4 x4 o (warp) Tension Modulus, ASTM D9-95 Strength and Poisson s Ratio x x x x 9 o (fill) Tension Strength ASTM D9-95 x4 x4 x4 x4 9 o (fill) Tension Modulus and ASTM D9-95 Strength x x x x o (warp) Compression Strength SACMA SRM -94 x6 x6 x6 x6 o (warp) Compression Modulus SACMA SRM -94 x x x x 9 o (fill) Compression Strength SACMA SRM -94 x6 x6 x6 x6 9 o (fill) Compression Modulus SACMA SRM -94 x x x x In-Plane Shear Strength ASTM D579-9 x4 x4 x4 x4 In-Plane Shear Modulus and ASTM D579-9 Strength x x x x Short Beam Shear ASTM D x Fiber Volume ASTM D7-9 One sample per panel Resin Volume ASTM D7-9 One sample per panel Void Content ASTM D74-94 One sample per panel Cured Neat Resin Density --- Supplied by manufacturer for material Glass Transition Temperature SACMA SRM 8-94 dry, wet per prepreg lot Notes : CTD: One prepreg lot of material tested (test temperature = o F, moisture content = as fabricated, soak time at 65 was min.) RTD: Three prepreg lots of material tested (test temperature = 7 o F, moisture content = as fabricated) ETW: Three prepreg lots of material tested (test temperature = 8 5 o F, moisture content = equilibrium per section.5., soak time at 8 was 6 sec.) 4 ETD: Three prepreg lots of material tested (test temperature = 8 5 o F, moisture content = as fabricated, soak time at 8 was 6 sec.) 5 Dry specimens are as fabricated specimens that have been maintained at ambient conditions in an environmentally controlled laboratory.

10 .5. Environmental Conditioning All wet conditioned samples were exposed to elevated temperature and humidity conditions to establish moisture saturation of the material. Specimens were exposed to 85 ± 5 % relative humidity and 45 ± 5 F until an equilibrium moisture weight gain of traveler, or witness coupons ( x x specimen thickness) was achieved. ASTM D59 and SACMA SRM were used as guidelines for environmental conditioning and moisture absorption. Effective moisture equilibrium was achieved when the average moisture content of the traveler specimen changed by less than.5% for two consecutive readings within a span of 7 ±.5 days and was expressed by: W i -W W b i - <.5 where W i = weight at current time W i- = weight at previous time W b = baseline weight prior to conditioning It is common to see small fluctuations in an unfitted plot of the weight gain vs. time curve. There were no fluctuations that made significant errors in results or caused rejection in the moisture equilibrium criteria. Once the traveler coupons passed the criteria for two consecutive readings, the samples were removed from the environmental chamber and placed in a sealed bag with a moist paper or cotton towel for a maximum of 4 days until mechanical testing. Strain gauged specimens were removed from the controlled environment for a maximum of hours for application of gages in ambient laboratory conditions..5. Fluid Sensitivity Screening All wet conditioned samples were exposed to elevated temperature and humidity conditions to establish moisture saturation of the material. Specimens were exposed to 85 ± 5 % relative humidity and 45 ± 5 F until an equilibrium moisture weight gain of traveler, or witness coupons ( x x specimen thickness) was achieved. ASTM D59 and SACMA SRM were used as guidelines for environmental conditioning and moisture absorption. Effective moisture equilibrium was achieved when the average moisture content of the traveler specimen changed by less than.5% for two consecutive readings within a span of 7 ±.5 days and was expressed by:

11 W i -W W b i - <.5 where W i = weight at current time W i- = weight at previous time W b = baseline weight prior to conditioning It is common to see small fluctuations in an unfitted plot of the weight gain vs. time curve. There were no fluctuations that made significant errors in results or caused rejection in the moisture equilibrium criteria. Once the traveler coupons passed the criteria for two consecutive readings, the samples were removed from the environmental chamber and placed in a sealed bag with a moist paper or cotton towel for a maximum of 4 days until mechanical testing. Strain gauged specimens were removed from the controlled environment for a maximum of hours for application of gages in ambient laboratory conditions..5.4 Normalization Procedures The normalization procedure attempts to reduce variability in fiber-dominated material properties by adjusting raw test values to a specified fiber volume content. Only the following properties were normalized: (warp) Tensile Strength and Modulus 9 (fill) Tensile Strength and Modulus (warp) Compressive Strength and Modulus 9 (fill) Compressive Strength and Modulus The normalization procedure was adopted from MIL-HDBK-7-E, section.4... The procedure which was used to normalize the data is based on two primary assumptions: The relationship between fiber volume fraction and ultimate laminate strength is linear over the entire range of fiber/resin ratios. (It neglects the effects of resin starvation at high fiber contents.) Fiber volume is not commonly measured for each test sample, so this method accounts for the fiber volume variation between individual test specimens by utilizing a relationship between fiber volume fraction and laminate cured ply thickness. This relationship is virtually linear in the.45 to.65 fiber volume fraction range. Additional information is detailed in FAA Document DOT/FAA/AR-/47: Material Qualification and Equivalency for Polymer Matrix Composite Material Systems. For all

12 normalized data contained in this document, the test values are normalized by cured ply thickness according to: where: CPT Normalized Value Test Value CPT specimen normalizing Average Sample Thickness CPT specimen # of plies.5.5 Statistical Analysis When compared to metallic materials, fiber reinforced composite materials exhibit a high degree of material property variability. This variability is due to many factors, including but not limited to: raw material and prepreg manufacture, material handling, part fabrication techniques, ply stacking sequence, environmental conditions, and testing techniques. This inherent variability drives up the cost of composite testing and tends to render smaller data sets than those produced for metallic materials. This necessitates the usage of statistical techniques for determining reasonable design allowables for composites. The analyses and design allowable generation for both A and B basis values were performed using the procedure detailed in section 5. of FAA Document DOT/FAA/AR- /47: Material Qualification and Equivalency for Polymer Matrix Composite Material Systems..5.6 Material Performance Envelope and Interpolation Using the B-basis numbers, a material performance envelope may be generated for the material system by plotting these values as a function of temperature. Figure.5. shows an example material performance envelope using B-basis values.

13 Actual Basis Value Estimated Value B-Basis Strength Values (ksi) 8 6 CTD Material Performance Envelope RTD RTW ETD ETW Temperature ( o F) Figure.5. Material performance envelope. Since each specific aircraft application of the qualified material may have different Material Operational Limits (MOL) than those tested in the material qualification (which is usually the upper limit), some applications may require a reduced MOL. In this case, simple linear interpolation may be used to obtain the corresponding basis values at the new application MOL. This interpolation may be accomplished using the following simple relationships assuming T RTD < T MOL < T ETD : For the corresponding MOL dry basis value, the interpolated basis value using the qualification data is B MOL B RTD BRTD BETD TRTD TMOL T T RTD ETD where B MOL = new application basis value interpolated to T MOL 4

14 B RTD = basis RTD strength value B ETD = basis ETD strength value T RTD = RTD test temperature T ETD = ETD test temperature T MOL = new application MOL temperature For the corresponding MOL wet basis value, an estimated Room Temperature Wet (RTW) value must be calculated. This may be accomplished by the simple relation B RTW B RTD ( B B ) ETW ETD The interpolated wet basis value using the qualification data may then be obtained by B MOL B RTW BRTW BETW TRTW TMOL T T RTW ETW where: B MOL = new application basis value interpolated to T MOL B RTW = estimated basis RTW strength value B ETW = basis ETW strength value T RTW = RTW (i.e., RTD) test temperature T ETW = ETW test temperature T MOL = new application MOL temperature These equations may also be used for interpolated mean strengths as well as A-basis values with the appropriate substitutions. It should be noted that because unforeseen material property drop-offs with respect to temperature and environment can occur, extrapolation to a higher MOL should not be attempted without additional testing and verification. In addition, the interpolation equations shown above are practical for materials obeying typical mechanical behavior. In most cases, some minimal amount of testing may also be required to verify the interpolated values Interpolation Example This section provides an example of linear interpolations to a specific application environment less than the tested upper material limit used in qualification. Assuming a specific application environment of 5 o F, Figure.5. depicts the linear interpolation of the B-basis design allowable to this environment. Using the above equations along with the nominal testing temperatures (see Table.5.), the interpolated basis values at 5 o F become 5

15 ETD : B MOL = 75.6 ksi ETW : B MOL = ksi Actual Basis Value Estimated Value CTD RTD B-Basis Strength Values (ksi) 8 6 RTW ETD ETW Temperature ( o F) Figure.5. Example of 5 o F interpolation for B-basis values. 6

16 . FIBERITE T65 K-7-PW / 774 PREPREG PROPERTIES 7

17 . Prepreg Documentation by Prepreg Lot Prepreg Documentation Prepreg Manufacturer & Product ID: HMF 774/T65-5-K-PW-95-4 Impregnation Method: SOLVENT Prepreg Batch or Lot # Batch (Lot) ID as labeled on samples Date of Manufacture Expiration Date Resin Content [%] 9% 8 % 8 % Reinforcement Areal Weight & Test Method 94 g/sq m 95 g/sq m 9 g/sq m Resin Flow & Test Conditions psi psi psi Gel Time & Test Conditions 77 C 77 C 77 C Volatile Content Reinforcement Documentation Fiber/Fabric Manufacturer & Product ID: T65/5 K 9NT Precursor Type: PAN Nominal Filament Count: K Finish/Sizing Type and %: UC9,.9.97% Nominal tow or yarn count/inch: Twist: not available Fabric Batch or Lot # BS8 BS8 BS6 Sizing weight, %.97 %.97 %.9% Date of Manufacture Average Fiber Density per Lot & Test Method.778 g/cc.778 g/cc.77 g/cc Matrix Documentation Resin Manufacturer & Product ID: Matrix Batch or Lot # Date of Manufacture Average Neat Resin Density by Lot & Test Method.7 g/ccm.7 g/ccm.7 g/ccm 8

18 . Process Specification This specification does not address issues relating to safety, quality control, bagging material selection, bagging procedure, tool preparation, or equipment selection. Although these may affect overall part quality, it is the responsibility of the end user to develop procedures related to these issues in a manner that produces parts with high quality and consistency. The following autoclave cure procedures are excerpts from Cessna process specification CSAC5. The exception to this specification is the cure cycle and ply orientation tolerance. The cure cycle for panel fabrication is 5 F, ± : for minutes, +6, -; 45 psi, ±5. Individual ply orientation is ± with respect to the tooled reference edge. The detailed cure cycle procedure is given below. All test specimens were cured per this specification by Cessna Aircraft Company. However, the effects of the upper and lower limits of vacuum, temperature, cure time, heat-up rate and hold temperature on the mechanical and thermal properties have not been investigated. () Apply in-hg of vacuum minimum to vacuum bag. Initiate autoclave pressure psi/minute minimum, vent bag at ± psig. Final vessel pressure 45±5 psi. () From F to 4 F, a minimum heat up rate of. F/minute is acceptable. () All thermocouples shall be at temperature 9

19 . FIBERITE T65 K-7-PW / 774 LAMINATE PROPERTIES

20 . Test Results

21 .. Summary MATERIAL: Fi beri te 774/T65 K-7-PW Graphi te 774/T65 K-7-PW PREPREG: Fi beri te HMF 774/T65-5-K-PW-95-4 Summary FIBER: Amoco T65/5 K 9NT RESIN: Fi beri te HMF 774 T g (dry): F T g (wet): 5.69 F T g METHOD: DMA (SRM 8-94) PROCESSING: Autocl ave cure: 5 F for 6, 45 5 psi Date of fiber manufacture 8/7/97 Date of testing /6/99-4/4/99 Date of resin manufacture /5/97 Date of data submittal 8/99 Date of prepreg manufacture //97 Date of analysis /7/99-4/4/99 Date of composite manufacture /9/98 4/6/98 F tu E t (ksi) 7. (6.) LAMINA MECHANICAL PROPERTY SUMMARY Data Reported as: Measured (Normalized by CPT=.79 in) CTD RTD ETD ETW B-Basis Mean B-Basis Mean B-Basis Mean B-Basis Mean 6.79 (6.) (Msi) (9.4) 7.77 (7.4) 5.88 (5.7) (9.69).99 (.7) 9.7 (9.) (8.9) 6.7 (6.44) 4.4 (4.69) (9.87) tu tu F t E cu F c E cu F c E su F (ksi) 5. (6.7) 7.64 (9.44) (Msi) ---. (.49) (ksi) 95. (9.59).7 (8.5) (Msi) (8.8) (ksi) 94.6 (9.76) 8.4 (7.87) (Msi) (9.) 8.5 (8.4) 9. (9.4) (9.77) 9.7 (9.9) 4.9 (4.7) (9.4) (84.66) (96.) (8.85) 4. (4.96) 4.8 (5.6) (8.77) 7. (7.9) 8.75 (8.) (9.46) 69.9 (67.65) 78.8 (76.98) (9.4).7 (.).6 (.7) (9.66) 5.5 (5.6) 59.8 (59.6) (9.47) 5.47 (5.8) 58.9 (58.65) (9.44) (ksi) G s (Msi) F su** (ksi) ** Apparent i nterl ami nar shear strength

22 .. Individual Test Summaries

23 ... Tension, -axis Material: Resin content: - 9 wt% Comp. density: g/cc Fiber volume: 5-58 vol% Void content:.8 to.4 % Ply thickness: in. Ply range: 4 plies Tension, -axis G/Ep [] 4 Test method: D9-95 Modulus calculation: linear fit from - Normalized by:.79 in. ply thickness CTD (B) RTD (A) ETD (G) ETW (F) Test Temperature [ F] Moisture Conditioning dry dry dry 6 days,.64-.7% wt gain Equilibrium at T, RH as fabricated as fabricated as fabricated 45 F, 85 % Source code BCJXXXXB BCJXXXXA BCJXXXXG BCJXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F tu (ksi) B-value A-value E t (Msi) t No. Specimens No. Prepreg Lots Mean Minimum Maximum C.V.(%) No. Specimens No. Prepreg Lots Mean No. Specimens No. Prepreg Lots 4

24 ... Tension, -axis Material: Resin content: - 4 wt% Comp. density: g/cc Fiber volume: 5-58 vol% Void content:. to.9 % Ply thickness: in. Ply range: 4 plies Tension, -axis G/Ep [] 4 Test method: D9-95 Modulus calculation: linear fit from - Normalized by:.79 in. ply thickness CTD (B) RTD (A) ETD (G) ETW (F) Test Temperature [ F] Moisture Conditioning dry dry dry 6 days,.6-.74% wt gain Equilibrium at T, RH as fabricated as fabricated as fabricated 45 F, 85 % Source code BCUXXXXB BCUXXXXA BCUXXXXG BCUXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F tu (ksi) B-value A-value E t (Msi) No. Specimens No. Prepreg Lots Mean Minimum Maximum C.V.(%) No. Specimens No. Prepreg Lots 5

25 ... Compression, -axis Material: Resin content: - 5 wt% Comp. density: g/cc Fiber volume: vol% Void content:.9 to 4. % Ply thickness: in. Ply range: 6 plies Compression, -axis G/Ep [] 6 Test method: SRM -94, D695-9 (mod) Modulus calculation: linear fit from - Normalized by:.79 in. ply thickness CTD (B) RTD (A) ETD (G) ETW (F) Test Temperature [ F] Moisture Conditioning dry dry dry 69 days,.6-.7% wt gain Equilibrium at T, RH as fabricated as fabricated as fabricated 45 F, 85 % Source code BCKXXXXB BCKXXXXA BCKXXXXG BCKXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F cu (ksi) B-value A-value E c (Msi) No. Specimens No. Prepreg Lots Mean Minimum Maximum C.V.(%) No. Specimens 6 6 No. Prepreg Lots 6 6

26 ...4 Compression, -axis Material: Resin content: 9-9 wt% Comp. density: g/cc Fiber volume: 5-6 vol% Void content:.7 to 5. % Ply thickness: in. Ply range: 6 plies Compression, -axis G/Ep [] 6 Test method: SRM -94, D695-9 (mod) Modulus calculation: linear fit from - Normalized by:.79 in. ply thickness CTD (B) RTD (A) ETD (G) ETW (F) Test Temperature [ F] Moisture Conditioning dry dry dry 5-67 days,.56-.7% wt gain Equilibrium at T, RH as fabricated as fabricated as fabricated 45 F, 85 % Source code BCWXXXXB BCWXXXXA BCWXXXXG BCWXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F cu (ksi) B-value A-value E c (Msi) No. Specimens No. Prepreg Lots Mean Minimum Maximum C.V.(%) No. Specimens 6 6 No. Prepreg Lots 6 7

27 ...5 Shear, axis Material: Resin content: 5-8 wt% Comp. density: g/cc Fiber volume: 5-55 vol% Void content:.8 to.5 % Ply thickness: in. Ply range: 8 plies Shear, -axis G/Ep [(/9) 4 /] S Test method: D579-9 Modulus calculation: linear fit from - 6 Normalized by: N/A CTD (B) RTD (A) ETD (G) ETW (F) Test Temperature [ F] Moisture Conditioning dry dry dry 7 days,.6-.7% wt gain Equilibrium at T, RH as fabricated as fabricated as fabricated 45 F, 85 % Source code BCNXXXXB BCNXXXXA BCNXXXXG BCNXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F su (ksi) B-value A-value G s (Msi) No. Specimens No. Prepreg Lots Mean Minimum Maximum C.V.(%) No. Specimens 6 7 No. Prepreg Lots 6 8

28 ...6 Shear, axis Material: Resin content: - 9 wt% Comp. density: g/cc Fiber volume: 5-59 vol% Void content:.6 to. % Ply thickness: in. Ply range: 4 plies Shear, -axis G/Ep [] 4 Test method: D44-89 Modulus calculation: N/A Normalized by: N/A Test Temperature [ F] Moisture Conditioning Equilibrium at T, RH Source code CTD (B) RTD (A) ETD (G) ETW (F) 75 dry as fabricated BCQXXXXA Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean.68 Minimum.6 Maximum.4 C.V.(%).4 F su (ksi) B-value 9.99 A-value 9.5 No. Specimens No. Prepreg Lots 8 NOTES: These values represent the apparent interlaminar shear properties and are to be used for quality control purposes only. Do not use these values for interlaminar shear strength design values. 9

29 .. Individual Test Charts

30 ... Tension, -axis Tension -- Normalized Strength Fabric 6 4 Strength (ksi) Conditioning X Dry O Wet Temperature ( F) NOTE: The symbols represent the pooled average of all tests, and the bars represent the upper and lower limit of the data. The 8 dry and wet data have been staggered for clarity.

31 ... Tension, -axis 9 Tension -- Normalized Strength Fabric 6 4 Strength (ksi) Conditioning X Dry O Wet Temperature ( F) NOTE: The symbols represent the pooled average of all tests, and the bars represent the upper and lower limit of the data. The 8 dry and wet data have been staggered for clarity.

32 ... Compression, -axis Compression -- Normalized Strength Strength (ksi) Conditioning X Dry O Wet Temperature ( F) NOTE: The symbols represent the pooled average of all tests, and the bars represent the upper and lower limit of the data. The 8 dry and wet data have been staggered for clarity.

33 ...4 Compression, -axis 9 Compression -- Normalized Strength Strength (ksi) Conditioning X Dry O Wet Temperature ( F) NOTE: The symbols represent the pooled average of all tests, and the bars represent the upper and lower limit of the data. The 8 dry and wet data have been staggered for clarity. 4

34 ...5 Shear, axis In-Plane Shear -- Measured Strength Fabric 8 4 Strength (ksi) Conditioning X Dry O Wet Temperature ( F) NOTE: The symbols represent the pooled average of all tests, and the bars represent the upper and lower limit of the data. The 8 dry and wet data have been staggered for clarity. 5

35 ...6 Shear, axis Apparent Interlaminar Shear -- Measured Strength Fabric 6 Strength (ksi) 8 4 Conditioning X Dry O Wet Temperature ( F) NOTE: The symbols represent the pooled average of all tests, and the bars represent the upper and lower limit of the data. 6

36 . Raw Data Specimen Naming Convention Test coupons were identified using an eight-digit specimen code, with the significance of each digit delineated below. A representative sample ID is shown for reference purposes. B C J 5 F st Character: Fabricator B designates Cessna nd Character: Material System C designates T65 K-7-PW / 774 rd Character: Test Type J designates Tension Strength and Modulus, other test types will be clearly labeled at the top of each sheet 4 th Character: Prepreg Batch ID See Table. for Fiberite Batch ID / Sample Batch ID correlation. 5 th Character: Panel Number The panel(s) fabricated for a specific test method. 6 th Character: Subpanel Number The sub-panel(s) cut from each panel, with subpanel numbers labeled increasing from reference edge. 7 th Character: Sample Number The sample(s) cut from each subpanel, with sample numbers labeled increasing from reference edge. 8 th Character: Test Condition A --- RTD B --- CTD F --- ETW G --- ETD See Table.5. for condition parameters. 7

37 .. Raw Data Spreadsheets and Scatter Charts 8

38 Tension-- (RTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] BCJXA BCJXA BCJXA BCJ4XA BCJ4XA BCJ4XA BCJXA BCJXA BCJXA BCJX6A BCJX7A BCJX8A BCJX6A BCJX7A BCJX8A BCJXA BCJXA BCJX4A BCJX6A Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec Number of Spec

39 6 Tension Tension -- (RTD) Normalized Strength Pooled Average = 5.77 [ksi] Pooled Standard Deviation = 4.9 [ksi] Pooled Coeff. of Variation =.95 [%] 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 6 Tension -- (RTD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation =.5 [Msi] Pooled Coeff. of Variation =.49 [%] 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 4

40 Tension -- (CTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] BCJX5B BCJX6B BCJX7B BCJ4X5B BCJ4X6B BCJ4X7B Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 Number of Spec. 6 4

41 6 Tension -- (CTD) Normalized Strength Pooled Average = 6.8 [ksi] Pooled Standard Deviation = 8. [ksi] Pooled Coeff. of Variation = 6.56 [%] 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 6 Tension -- (CTD) Normalized Modulus Pooled Average = 9.4 [Msi] Pooled Standard Deviation =.97 [Msi] Pooled Coeff. of Variation = 4.6 [%] 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 4

42 Tension -- (ETW) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] BCJXF BCJXF BCJXF BCJX4F BCJX5F BCJXF BCJXF BCJXF BCJX4F BCJX5F BCJXF BCJXF BCJXF BCJX4F BCJX5F BCJXF BCJXF BCJXF BCJX4F BCJX5F BCJXF BCJXF BCJXF BCJX4F BCJX5F BCJ4XF BCJ4XF BCJ4XF BCJ4X4F BCJ4X5F Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 6 Number of Spec. 6 4

43 Tension -- (ETW) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = 5.45 [ksi] Pooled Coeff. of Variation = 4.4 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 6 Tension -- (ETW) Normalized Modulus Pooled Average = 9.87 [Msi] Pooled Standard Deviation =.4 [Msi] Pooled Coeff. of Variation = 4.65 [%] 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 44

44 Tension-- (ETD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] BCJX6G BCJX7G BCJX8G BCJX6G BCJX7G BCJX8G BCJX5G BCJX6G BCJX7G BCJ4XG BCJ4XG BCJ4XG BCJXG BCJXG BCJXG BCJ4X6G BCJ4X7G BCJ4X8G Average Average norm Standard Dev Standard Dev. norm..47 Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec Number of Spec

45 6 Tension -- (ETD) Normalized Strength Pooled Average = 9.5 [ksi] Pooled Standard Deviation =. [ksi] Pooled Coeff. of Variation =.49 [%] 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 6 Tension -- (ETD) Normalized Modulus Pooled Average = 8.95 [Msi] Pooled Standard Deviation =.47 [Msi] Pooled Coeff. of Variation = 5.9 [%] 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 46

46 9 Tension-- (RTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCUXA BCUXA BCUXA BCU4XA BCU4XA BCU4XA BCUX6A BCUX7A BCUX8A BCUXA BCUX4A BCUX6A BCUXA BCUXA BCUXA BCUX6A BCUX7A BCUX8A Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

47 9 Tension -- (RTD) Normalized Strength Pooled Average = 9.46 [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = 5.58 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 9 Tension -- (RTD) Normalized Modulus Pooled Average = 9.77 [Msi] Pooled Standard Deviation =.8 [Msi] Pooled Coeff. of Variation =.88 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 48

48 9 Tension-- (CTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCUX5B BCUX6B BCUX7B BCU4X5B BCU4X7B BCU4X8B Average Average norm Standard Dev Standard Dev. norm 5.6. Coeff. of Var. [%].7.67 Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 Number of Spec. 6 49

49 9 Tension -- (CTD) Normalized Strength Pooled Average = 9.46 [ksi] Pooled Standard Deviation = 5.6 [ksi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 9 Tension -- (CTD) Normalized Modulus Pooled Average =.489 [Msi] Pooled Standard Deviation =. [Msi] Pooled Coeff. of Variation =.9 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 5

50 9 Tension-- (ETW) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCUXF BCUXF BCUXF BCUX4F BCUX5F BCUXF BCUXF BCUXF BCUX4F BCUX5F BCUXF BCUXF BCUXF BCUX4F BCUX5F BCU4X5F BCU4X6F BCU4X7F BCU4X8F BCU4X9F BCUXF BCUXF BCUXF BCUX4F BCUX5F BCUXF BCUXF BCUXF BCUX4F BCUX5F Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 Number of Spec. 6 5

51 9 Tension -- (ETW) Normalized Strength Pooled Average =.75 [ksi] Pooled Standard Deviation = 6.4 [ksi] Pooled Coeff. of Variation = 5.4 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 9 Tension -- (ETW) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation =.77 [Msi] Pooled Coeff. of Variation =.8 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 5

52 9 Tension-- (ETD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCUX6G BCUX7G BCUX8G BCUX6G BCUX7G BCUX8G BCUXG BCUXG BCUXG BCU4XG BCU4XG BCU4XG BCUX5G BCUX6G BCUX7G BCU4XG BCU4XG BCU4XG Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

53 9 Tension -- (ETD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = 6.66 [ksi] Pooled Coeff. of Variation = 5.57 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Tension Strength [ksi] 9 Tension -- (ETD) Normalized Modulus Pooled Average = 8.77 [Msi] Pooled Standard Deviation =.48 [Msi] Pooled Coeff. of Variation =.686 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Tension Modulus [Msi] 54

54 Compression -- (RTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCK6A BCK7A BCK8A BCLX6A BCK8A BCK9A BCKBA BCLX6A BCK6A BCK7A BCK8A BCLX6A BCK6A BCK8A BCK9A BCLX6A BCK7A BCK8A BCKAA BCLX6A BCK7A BCK8A BCK9A BCLX6A Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

55 Compression -- (RTD) Normalized Strength Pooled Average = 4.65 [ksi] Pooled Standard Deviation = 5.9 [ksi] Pooled Coeff. of Variation = 5.67 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] Compression -- (RTD) Normalized Modulus Pooled Average = 9.4 [Msi] Pooled Standard Deviation =.5 [Msi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 56

56 Compression -- (CTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCLX9B BCLX9B BCKB BCKB BCK4B BCK6B BCK7B BCK8B Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 Number of Spec. 6 57

57 Compression -- (CTD) Normalized Strength Pooled Average = 8.5 [ksi] Pooled Standard Deviation = 4.6 [ksi] Pooled Coeff. of Variation = 4. [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] Compression -- (CTD) Normalized Modulus Pooled Average = 8.84 [Msi] Pooled Standard Deviation =.5 [Msi] Pooled Coeff. of Variation =.99 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 58

58 Compression -- (ETW) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCKF BCKF BCKF BCK4F BCK5F BCLXF BCKF BCK4F BCK5F BCK6F BCK7F BCLXF BCKF BCKF BCKF BCK4F BCK5F BCLXF BCKF BCKF BCKF BCK4F BCK5F BCLXF BCKF BCKF BCK4F BCK5F BCK6F BCLXF BCKF BCKF BCKF BCK4F BCK5F BCLXF Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 Number of Spec. 6 59

59 Compression -- (ETW) Normalized Strength Pooled Average = 59.6 [ksi] Pooled Standard Deviation = 6.4 [ksi] Pooled Coeff. of Variation =.4 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] Compression -- (ETW) Normalized Modulus Pooled Average = 9.47 [Msi] Pooled Standard Deviation =.77 [Msi] Pooled Coeff. of Variation = 8.5 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 6

60 Compression -- (ETD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCK9G BCKAG BCKBG BCLXCG BCK7G BCK8G BCKAG BCLXCG BCK9G BCKAG BCKBG BCLX9G BCKG BCKG BCKG BCLX9G BCK6G BCK8G BCK9G BCLX9G BCKG BCKG BCKG BCLX9G Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

61 Compression -- (ETD) Normalized Strength Pooled Average = 8.8 [ksi] Pooled Standard Deviation = 4.65 [ksi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] Compression -- (ETD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation =.7 [Msi] Pooled Coeff. of Variation =.8 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 6

62 9 Compression -- (RTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCWA BCWA BCWA BCZX7A BCWA BCWA BCWA BCZX6A BCW7A BCW8A BCW9A BCZX6A BCW6A BCW7A BCW8A BCZX6A BCWXA BCWXA BCWX4A BCW6A BCW7A BCW8A BCZX6A BCZX6A Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

63 9 Compression -- (RTD) Normalized Strength Pooled Average = 96. [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = 5.87 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] 9 Compression -- (RTD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation =.487 [Msi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 64

64 9 Compression -- (CTD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCW5B BCW6B BCW7B BCZX9B BCWB BCW4B BCW5B BCZX9B Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 Number of Spec. 6 65

65 9 Compression -- (CTD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = 4.78 [ksi] Pooled Coeff. of Variation = 4.74 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] 9 Compression -- (CTD) Normalized Modulus Pooled Average = 9.4 [Msi] Pooled Standard Deviation =.6 [Msi] Pooled Coeff. of Variation =.96 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 66

66 9 Compression -- (ETW) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCW8F BCW9F BCWAF BCWBF BCWCF BCZXF BCW8F BCW9F BCWBF BCZXF BCWF BCWF BCWF BCW4F BCW5F BCZXF BCWF BCWF BCWF BCW4F BCW5F BCZXF BCWF BCWF BCWF BCW4F BCW5F BCZXF BCWF BCWF BCWF BCW4F BCW5F BCZXF Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

67 9 Compression -- (ETW) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = 4.5 [ksi] Pooled Coeff. of Variation = 7.5 [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] 9 Compression -- (ETW) Normalized Modulus Pooled Average = 9.44 [Msi] Pooled Standard Deviation =.654 [Msi] Pooled Coeff. of Variation = 6.9 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 68

68 9 Compression -- (ETD) Strength & Modulus normalizing t ply [in].79 Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] BCW9G BCWAG BCWBG BCZXCG BCW7G BCW9G BCWAG BCZXCG BCWG BCWG BCWG BCZX9G BCWG BCWG BCW6G BCZXAG BCWX6G BCWX7G BCWX9G BCWG BCWG BCWG BCZX9G BCZX9G Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 8 6 Number of Spec

69 9 Compression -- (ETD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = 6.54 [ksi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepeg Lot # Compression Strength [ksi] 9 Compression -- (ETD) Normalized Modulus Pooled Average = 9.4 [Msi] Pooled Standard Deviation =.5 [Msi] Pooled Coeff. of Variation = 6.69 [%] 6 5 ASAP Batch # 4 Prepreg Lot # Compression Modulus [Msi] 7

70 In-Plane Shear -- (RTD) Strength & Modulus Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] BCN6A BCN7A BCN8A BCN9A BCNAA BCN6A BCN7A BCN8A BCN9A BCNAA BCN6A BCN7A BCN8A BCN9A BCNAA BCN6A BCN7A BCN8A BCN9A BCNAA BCNA BCNA BCN4A BCN5A BCN6A BCN7A BCN8A BCNAA Average Standard Dev..4.4 Coeff. of Var. [%] Min Min..75 Max Max..8 Number of Spec

71 In-Plane Shear -- (RTD) Measured Strength Pooled Average 8.87 [ksi] Pooled Standard Deviation =.4 [ksi] Pooled Coeff. of Variation =.78 [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Strength [ksi] In-Plane Shear -- (RTD) Measured Modulus Pooled Average =.667 [Msi] Pooled Standard Deviation =.4 [Msi] Pooled Coeff. of Variation = 6.49 [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Modulus [Msi] 7

72 In-Plane Shear -- (CTD) Strength & Modulus Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] BCN8B BCN9B BCNAB BCN6B BCN7B BCN8B Average Standard Dev..57. Coeff. of Var. [%] Min Min..79 Max Max..8 Number of Spec. 6 7

73 In-Plane Shear -- (CTD) Measured Strength Pooled Average 4.76 [ksi] Pooled Standard Deviation =.57 [ksi] Pooled Coeff. of Variation =.8 [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Strength [ksi] In-Plane Shear -- (CTD) Measured Modulus Pooled Average =.75 [Msi] Pooled Standard Deviation =. [Msi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Modulus [Msi] 74

74 In-Plane Shear -- (ETW) Strength & Modulus Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] BCNF BCNF BCN4F BCN5F BCNF BCNF BCN4F BCN5F BCNF BCNF BCN4F BCN5F BCNF BCNF BCN4F BCN5F BCN6F BCN7F BCN8F BCNAF BCNF BCNF BCN4F BCN5F Average Standard Dev..55. Coeff. of Var. [%] Min Min..76 Max Max..8 Number of Spec

75 In-Plane Shear -- (ETW) Measured Strength Pooled Average.859 [ksi] Pooled Standard Deviation =.55 [ksi] Pooled Coeff. of Variation = 5.7 [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Strength [ksi] In-Plane Shear -- (ETW) Measured Modulus Pooled Average =.46 [Msi] Pooled Standard Deviation =. [Msi] Pooled Coeff. of Variation = [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Modulus [Msi] 76

76 In-Plane Shear -- (ETD) Strength & Modulus Specimen Cure Prepreg ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Cycle Lot # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] BCNG BCNG BCNG BCN4G BCNG BCNG BCN4G BCN5G BCNG BCNG BCN4G BCN5G BCNG BCNG BCN4G BCN6G BCN7G BCN6G BCN7G BCN8G BCN9G BCNG BCNG BCN4G BCN8G BCN9G BCNG Average Standard Dev Coeff. of Var. [%] Min Min..75 Max Max..8 Number of Spec

77 In-Plane Shear -- (ETD) Measured Strength Pooled Average 4.44 [ksi] Pooled Standard Deviation =.474 [ksi] Pooled Coeff. of Variation =.5 [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Strength [ksi] In-Plane Shear -- (ETD) Measured Modulus Pooled Average =.465 [Msi] Pooled Standard Deviation =.84 [Msi] Pooled Coeff. of Variation = 8.78 [%] 6 5 ASAP Batch # 4 Prepreg Lot # In-Plane Shear Modulus [Msi] 78

78 Apparent Interlaminar Shear -- (RTD) Strength Fabric Specimen Cure Prepreg ASAP Strength Avg. Specimen # Plies in Avg. t ply Number Cycle Lot # Batch # [ksi] Thickn. [in] Laminate [in] BCQA BCQA BCQA BCQ4A BCQ5A BCQ6A BCQA BCQA BCQA BCQ4A BCQ5A BCQ6A BCQA BCQA BCQA BCQ4A BCQ5A BCQ6A Average Standard Dev..46 Coeff. of Var. [%].9 Min..6 Min..7 Max..7 Max..8 Number of Spec. 8 79

79 Apparent Interlaminar Shear -- (RTD) Measured Strength Fabric Pooled Average =.679 [ksi] Pooled Standard Deviation =.46 [ksi] Pooled Coeff. of Variation =.9 [%] ASAP Batch # Prepreg Lot # Apparent Interlaminar Shear Strength [ksi] 8

80 .. Fluid Sensitivity Raw Data Spreadsheets and Scatter Charts 8

81 In-Plane Shear -- (MEK - RTD) Strength Specimen Batch Strength Avg. Specimen # Plies in Avg. t ply Number Number [ksi] Thickn. [in] Laminate [in] BCN7T BCN9T BCNAT BCNAT BCNAT Average Standard Dev..7 Coeff. of Var. [%].6 Min. 8.7 Min..76 Max Max..8 Number of Spec. 5 In-Plane Shear -- (MEK - RTD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation =.7 [ksi] Pooled Coeff. of Variation =.6 [%] Batch # In-Plane Shear Strength [ksi] 8

82 In-Plane Shear -- (JP-4 JET FUEL - ETD) Strength Specimen Batch Strength Avg. Specimen # Plies in Avg. t ply Number Number [ksi] Thickn. [in] Laminate [in] BCNR BCNR BCN4R BCN5R BCN6R Average Standard Dev..68 Coeff. of Var. [%]. Min..59 Min..78 Max..894 Max..79 Number of Spec. 5 In-Plane Shear -- (JP-4 JET FUEL - ETD) Measured Strength Pooled Average =.685 [ksi] Pooled Standard Deviation =.68 [ksi] Pooled Coeff. of Variation =. [%] Batch # In-Plane Shear Strength [ksi] 8

83 In-Plane Shear -- (Hydraulic Fluid - ETD) Strength Specimen Batch Strength Avg. Specimen # Plies in Avg. t ply Number Number [ksi] Thickn. [in] Laminate [in] BCN6V BCN7V BCN8V BCN9V BCNAV Average Standard Dev..8 Coeff. of Var. [%].6 Min..84 Min..79 Max..64 Max..8 Number of Spec. 5 In-Plane Shear -- (Hydraulic Fluid - ETD) Measured Strength Pooled Average =.449 [ksi] Pooled Standard Deviation =.8 [ksi] Pooled Coeff. of Variation =.6 [%] Batch # In-Plane Shear Strength [ksi] 84

84 Fluid Sensitivity Comparison: Average In-Plane Shear Strength with Fluid (ksi) MEK (RTD) Same Environment In-Plane Shear Strength without Fluid (ksi) (RTD) Worst Case Environment In-Plane Shear Strength (ksi) (ETW) The RTD average in-plane shear strength was reduced by % after exposure to MEK. However it remained 7% higher than water exposure in ETW conditions. Average In-Plane Shear Strength with Fluid (ksi) JP-4 JET FUEL (ETD).69 Same Environment In-Plane Shear Strength without Fluid (ksi) (ETD) 4.4 Worst Case Environment In-Plane Shear Strength (ksi) (ETW).86 The ETD average in-plane shear strength was reduced by % after exposure to MEK. However it remained 6% higher than water exposure in ETW conditions. Average In-Plane Shear Strength with Fluid (ksi) HYDRAULIC FLUID (ETD) Same Environment In-Plane Shear Strength without Fluid (ksi) (ETD) Worst Case Environment In-Plane Shear Strength (ksi) (ETW) The ETD average in-plane shear strength was reduced by 5% after exposure to MEK. However it remained 4% higher than water exposure in ETW conditions. 85

85 .. Representative Shear Stress-Strain Curve The following stress-strain curve is representative of the T65 K-7-PW / 774 prepreg system. The tension and compression stress-strain curves are not presented in graphical form. If strain design allowables from these tests are required, simple one-dimensional linear stress-strain relationships may be used to obtain corresponding strain design values. This process should approximate tensile and compressive strain behavior relatively well but may produce extremely conservative strain values in shear due to the nonlinear behavior. A more realistic approach for shear strain design allowables is to use a maximum strain value of 5% (reference MIL-HDBK-7-E, section 5.7.6). If a nonlinear analysis of the material s shear behavior is required, the curve-fit of the shear stress-strain curve may be used. The representative shear stress-strain curve was obtained by taking the average of all the sample shear curves and determining the best-fit line through the data. The actual data points also presented on the chart to demonstrate material variability. 86

86 Shear Stress vs. Shear Strain, RTD 6 4 Shear Stress [psi] y - = a+blnx/x r = a = e-5 b = e Shear Strain [in/in] 87

87 . Statistical Results 88

88 .. Plot by Condition 89

89 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Tension - BCJXXXXX Measured 9

90 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Tension - BCJXXXXX Normalized 9

91 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Tension - BCUXXXXX Measured 9

92 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Tension - BCUXXXXX Normalized 9

93 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Compression - BCKXXXXX Measured 94

94 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Compression - BCKXXXXX Normalized 95

95 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Compression - BCWXXXXX Measured 96

96 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Compression - BCWXXXXX Normalized 97

97 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE In-Plane Shear - BCNXXXXX Measured 98

98 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Cessna CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Apparent Interlaminar Shear - BCQXXXXX Measured 99

99 .. Plot of Pooled Data

100 DISTRIBUTION OF POOLED DATA Cessna Tension - BCJXXXXX Measured..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE

101 DISTRIBUTION OF POOLED DATA Cessna Tension - BCJXXXXX Normalized..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE

102 DISTRIBUTION OF POOLED DATA Cessna 9 Tension - BCUXXXXX Measured..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE

103 DISTRIBUTION OF POOLED DATA Cessna 9 Tension - BCUXXXXX Normalized..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE 4

104 DISTRIBUTION OF POOLED DATA Cessna Compression - BCKXXXXX Measured..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE 5

105 DISTRIBUTION OF POOLED DATA Cessna Compression - BCKXXXXX Normalized..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE 6

106 DISTRIBUTION OF POOLED DATA Cessna 9 Compression - BCWXXXXX Measured..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE 7

107 DISTRIBUTION OF POOLED DATA Cessna 9 Compression - BCWXXXXX Normalized..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE 8

108 DISTRIBUTION OF POOLED DATA Cessna In-Plane Shear - BCNXXXXX Measured..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE 9

109 DISTRIBUTION OF POOLED DATA Cessna Apparent Interlaminar Shear - BCQXXXXX Measured..9.8 PROBABILITY OF SURVIVAL NORMALIZED VALUE

110 .4 Moisture Conditioning History Charts

111 Conditioning History Cessna BCJ BCJ4 BCJ BCJ BCJ BCJ BCJ Time (days) % Weight Gain (Total) Conditioning History Cessna Time (days) BCU BCU BCU BCU4 BCU4 BCU BCU

112 Conditioning History Cessna % Weight Gain (Total) Time (days) BCKF BCKF BCKF BCKF BCKF BCKF BCKF Conditioning History Cessna Time (days) BCLXF BCLXF BCLXF BCLXF BCLXF BCLXF BCLXF

113 Conditioning History Cessna BCWX BCWX BCWX BCWX BCWX BCWX BCWX Time (days) Conditioning History Cessna BCN BCN BCN BCN BCN BCN BCN Time (days) 4

114 Conditioning History Cessna % Weight Gain (Total) Time (days) BCZ BCZ BCZ BCZ BCZ BCZ BCZ Conditioning History Cessna Time (days) BCD BCD BCD 5

115 .5 Physical Test Results 6

116 Physical Test Summary Composite Resin Fiber Void Density Content Volume Content [g/cc] [wt%] [vol%] [vol%] Tension (BCJXXXXX) No. of Specimens Mean Standard Deviation Tension (BCUXXXXX) No. of Specimens Mean Standard Deviation Compression (BCKXXXXX) No. of Specimens Mean Standard Deviation Compression (BCWXXXXX) No. of Specimens Mean Standard Deviation In-Plane Shear (BCNXXXXX) No. of Specimens Mean Standard Deviation Interlaminar Shear (BCQXXXXX) No. of Specimens Mean Standard Deviation Overall No. of Specimens Overall Mean Overall Std. Deviation

117 COMPANY : MATERIAL SYSTEM : PROJECT : Cessna 9849C DMA Results -- Onset Storage Modulus DRY WET As Fabricated Moisture Equilibirum at 85% RH Sample # Tg [ C] Tg [ F] Sample # Tg [ C] Tg [ F] BCDXFA BCDXBC BCDXGA BCDXCC BCDXHA BCDXDC BCDXFA BCDXBC BCDXGA BCDXCC BCDXHA BCDXDC BCDXFA BCDXBC BCDXGA BCDXCC BCDXHA BCDXDC Average [ F] Average [ F] 5.69 Standard Dev. [ F] 4.9 Standard Dev. [ F].76 Coeff. Of Var. [%]. Coeff. Of Var. [%].86 DRY DMA Results - Peak Tan Delta As Fabricated Moisture Equilibirum at 85% RH Sample # Tg [ C] Tg [ F] Sample # Tg [ C] Tg [ F] BCDXFA BCDXBC.4.5 BCDXGA BCDXCC.9.7 BCDXHA BCDXDC BCDXFA BCDXBC BCDXGA BCDXCC.. BCDXHA BCDXDC BCDXFA BCDXBC BCDXGA BCDXCC BCDXHA BCDXDC WET Average [ F] 7.7 Average [ F].9 Standard Dev. [ F].67 Standard Dev. [ F] 4.57 Coeff. Of Var. [%].6 Coeff. Of Var. [%].97 8

118 BCDXFA BCDXGA 9

119 BCDXHA BCDXFA

120 BCDXGA BCDXHA

121 BCDXFA BCDXGA

122 Figure. BCDXHA BCDXBC

123 Figure. BCDXCC BCDXDC 4

124 BCDXBC BCDXCC 5

125 BCDXDC BCDXBC 6

126 BCDXCC BCDXDC 7

127 4. TESTING AND REPORTING COMMENTS 8

128 All tests were conformed under Designated Option Authority (DOA) by Cessna Aircraft Co., Inc. 9

129 APPENDIX A. PHYSICAL TEST DATA SUPPLIED BY MATERIAL VENDOR

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136 7