FAA/NASA Workshop on Composite Material Control Mark Freisthler Allen Fawcett Rod Osborne

1. FAA/NASA Workshop on Composite Material Control Mark Freisthler Allen Fawcett Rod Osborne August 2002

2. FAA/NASA Workshop on Composite Material ControlBoeing Material Qualification & Certification Philosophy Established Methods, Processes and Specifications that ensure the engineering material requirements of the design are met with a high degree of confidence and reliability

3. FAA/NASA Workshop on Composite Material ControlGeneral Boeing Requirements Any set of Material/Process Specifications must: • Ensure the continued certification basis of a product • Allow the product to be economically produced • Permit limited modifications to account for local production conditions • Be responsive to the company’s changing requirements

4. FAA/NASA Workshop on Composite Material ControlWhat Industry Specifications Must Accomplish to Provide Value to Boeing • Lower cost • Qualification/Certification of new materials • Lower production cost • Faster implementation time • Commonality of specifications, methods and processes, and database requirements • Rapid response to user needs • Enable global standardization of specification requirements

5. FAA/NASA Workshop on Composite Material ControlAir Framer’s Considerations • Documented controls must be established • The intended use of product has been identified • Level of certification documentation has been identified • Any new manufacturing technology must have a stable and repeatable product

6. FAA/NASA Workshop on Composite Material ControlAir Framer’s Concerns • Overly conservative design values • Inability to adapt to vendor unique circumstances • Loss of product consistency over time • Unknown variability of key mechanical properties

7. FAA/NASA Workshop on Composite Material ControlDesign Value Basics • Design Values do not control a product, but reflect the control placed on the product • The analytical tools used in design dictate the parameters for which Design Values are derived • Design Values must reflect actual in-use conditions • Design Values must reflect materials & processes actually used in production

8. FAA/NASA Workshop on Composite Material ControlCertification Balance Spec Controls and Allowables & Analysis Methods in Place Premium Selection or Point Design Certification Requirements Material & Process Specifications Performance Goals OR Methods & Allowables FAA/JAA Regulations Testing Requirements Criteria The more the materials and processes are under control and Methods & Allowables understood, the less testing is required for certification 8

9. FARs A B FAA/NASA Workshop on Composite Material ControlProduct & Design Connection + = Manufacturing Processes Material Purchased Manufacturing Processes Product Material & Processing Standards Material Specification Process Specification + + Engineering Processes = Prediction of Material Behavior (Design Values) Prediction of Structural Behavior (Design Analysis) Verification & Certification Tests Certification Basis Engineering Requirements & Standards Arrows Denote Delivery Tools (Paper and/or Electronic) Published Design Manuals (Design Analysis & Allowables) 9

10. FAA/NASA Workshop on Composite Material ControlCompatibility Between Internal and External Documentation End User Requirements Internal Process Specification The Proposed “Bridge” • DOT • FAA • AR-02 • XX Material Supplier Industry Specification Material Specification Process Used to Produce Test Parts