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Nex. Gen Burner Update International Aircraft Materials Fire Test Working Group Meeting October 21, Nex. Gen Burner Update International Aircraft Materials Fire Test Working Group Meeting October 21, 2009 Atlantic City, NJ Federal Aviation Administration

Outline • Background • Nex. Gen Burner Drawings • Recent findings Burnthrough Update IAMFTWG, Outline • Background • Nex. Gen Burner Drawings • Recent findings Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 2

What is a Nex. Gen Burner? • • The next generation (Nex. Gen) burner What is a Nex. Gen Burner? • • The next generation (Nex. Gen) burner was designed by the FAA Technical Center to be used as an equivalent burner to the Park DPL 3400 which is no longer in production The Nex. Gen burner relies on the same operating principles as the Park DPL 3400, which was designed for home heating purposes – – • Oil burner fuel nozzle, 80°hollow cone, 6. 0 gph Air flow approx 1350 fpm exiting draft tube Average flame temperature ~ 1900°F Average flame heat flux ~ 15 BTU/ft 2 s The Nex. Gen burner uses compressed air and fuel to supply the burner, whereas the Park DPL 3400 uses an electric motor to spin a blower fan and mechanical fuel pump – Air Flow Metering: • • – Nex. Gen Burner Park uses a butterfly throttle valve Nex. Gen uses a sonic orifice Fuel Pressure • • • Park DPL 3400 Park uses pressure regulator on pump Nex. Gen uses fuel tank head pressure Major advantages of a Nex. Gen burner: – – – Precise metering of inlet parameters Can be constructed in-house with easily obtainable materials Can be easily modified for future upgrades (as a result of FAATC research) Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 3

Nex. Gen Drawings • Drawings are available online at http: //www. fire. tc. faa. Nex. Gen Drawings • Drawings are available online at http: //www. fire. tc. faa. gov/pdf/materials/Nex. Gen. Plans. pdf Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 4

Remanufactured Stators and Turbulators • Marlin. Engineering, Inc was able to digitize the original Remanufactured Stators and Turbulators • Marlin. Engineering, Inc was able to digitize the original stator and turbulator • Irregularities were corrected in design software, symmetry was restored to design • A computer numerical controlled (CNC) mill was used to cut new, corrected stators and turbulators • The new prototypes were sent to the FAA Tech Center for evaluation and comparison with a properly configured Nex. Gen burner Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 5

Front View Original Turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Prototype Turbulator Federal Aviation Front View Original Turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Prototype Turbulator Federal Aviation Administration 6

Rear View Original Turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Prototype Turbulator Federal Aviation Rear View Original Turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Prototype Turbulator Federal Aviation Administration 7

Original Turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Prototype Turbulator Federal Aviation Administration 8 Original Turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Prototype Turbulator Federal Aviation Administration 8

Prototype Stator Burnthrough Update IAMFTWG, Atlantic City, NJ Original Modified Stator Federal Aviation Administration Prototype Stator Burnthrough Update IAMFTWG, Atlantic City, NJ Original Modified Stator Federal Aviation Administration 9

Comparison Tests • Datum: – FAA Nex. Gen 2 burner – Constructed as per Comparison Tests • Datum: – FAA Nex. Gen 2 burner – Constructed as per FAA Nex. Gen burner guidelines (http: //www. fire. tc. faa. gov/pdf/materials/Nex. Gen. Plans. pdf) • A new draft tube was made to fit the precise 4” round stator – – Original 4” i. d. pipe is not perfectly round Stator could have been cut, but then we would have 2 imperfect parts Tube was honed out to precisely fit the new stator In the future, extruded tube with tight tolerance may be necessary for reengineered CNC stators Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 10

Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 11 Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 11

Comparison Tests • Testing was performed on the picture frame sample holder with polyacrylonitrile Comparison Tests • Testing was performed on the picture frame sample holder with polyacrylonitrile (PAN) materials of 2 densities • Samples were kept in conditioning chamber until testing Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 12

Average of 4 Tests Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 13 Average of 4 Tests Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 13

Results • The new stator and turbulator had no significant effect on overall flame Results • The new stator and turbulator had no significant effect on overall flame temperature or burnthrough times of PAN materials • These new parts could be considered equivalent to the Monarch H 215 stator and F 124 turbulator Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 14

Nex. Gen, Burnthrough, and PIV Task Group • Discuss plans, construction of burner with Nex. Gen, Burnthrough, and PIV Task Group • Discuss plans, construction of burner with those interested in building a burner • Discuss remanufactured stator and turbulator • Nex. Gen burner for other tests (seat cushion, cargo liner, powerplants) Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 15

Questions? Contact: Robert Ochs DOT/FAA Tech Center BLDG 287 Atlantic City Int’l Airport NJ Questions? Contact: Robert Ochs DOT/FAA Tech Center BLDG 287 Atlantic City Int’l Airport NJ 08405 robert. [email protected] gov 1 609 485 4651 Burnthrough Update IAMFTWG, Atlantic City, NJ Federal Aviation Administration 16