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Aircraft Industry Input on FAA Certification Methods for VARTM Process Materials
The following survey is your opportunity to help form new FAA policies and requirements. It will take only 5-10 minutes to complete. Thank you for your time.
1.
Do you currently use or have used any type of resin molding process for building of materials/products?
Yes
No
2.
Are you aware of the FAA document DOT/FAA/AR-06/25 that describes guidelines for development and use of resin molded materials?
Yes
No
3.
For varying resin chemistries, which additional verification methods are used to ensure the appropriate mixing or to analyze the ingredients present?
HPLC
FTIR
Thermal Testing (i.e. DMA, DSC, etc.)
Viscosity
4.
What tests performed at the resin level are provided by your supplier's process specifications or receiving information?
HPLC
FTIR
Thermal Testing (i.e. DMA, DSC, etc.)
Viscosity
Color
Gel
Flow
5.
If blending resin batches, what chemical analysis tests are used to determine the nature and type of the blending?
HPLC
FTIR
Thermal Testing (i.e. DMA, DSC, etc.)
Viscosity
Color
Gel
Flow
6.
How useful do you find the color of the resin at different stages in the process in providing information about the quality of a batch? (pg 16)
Very helpful
Somewhat helpful
Not helpful
If used, list the appropriate methods:
7.
Does the tracking policy implemented by your material suppliers of resin provide documentation of the following? (Select all provided).
Temperature logs of freezers
Out times of materials
Regulations for freezing
8.
Which of the following describe how qualified employees of varied levels are to produce composites using your process specifications?
Tech 1 qualified at all methods
Tech 1 qualified at several methods
Tech 1 qualified at limited methods
Tech 2 qualified at all methods
Tech 2 qualified at several methods
Tech 3 qualified at all methods
Tech 3 qualified at advanced methods
9.
When testing resin samples from the mixed batch, do you test for ultimate Tg?
Yes
No
10.
If so, what test method is used?
DMA
DSC
TMA
Modulated DSC
No test for ultimate Tg
11.
When carrying out resin infusion, which factors do you take into consideration to determine the number of thermocouples necessary for adequate measurements for a large panel?
Thickness
Resin viscosity
Total area
Ramp rate
Heat survey
12.
When inspecting a panel after cure, do you use any of the following to determine whether the resin is sufficiently cured? (select all tests used)
Chemical tests
Thermal tests
Physical tests
NDI
Visual tests
If yes, please specify which methods:
13.
When testing the physical properties of your cured composites, do you test for thermal induced microcracking from scenarios like temperature cycles or heat -up spikes?
Yes
No
If so, please specify which method and list why you choose to do so:
14.
How long do you keep records of your raw batch ingredients?
1 year
3 years
5 years
7 years
10 years
15.
What are your guidelines for mixing of resin and fiber batches?
Any batch of resin mixed with another
Any batch of fiber mixed with another
Mix only three lots of resin
Mix only three lots of fiber
Mix only consecutive batches of resin
Mix only consecutive batches of fiber
No mixing of resin batches
No mixing of fiber batches
16.
When dealing with qualification baseline enhancement after an initial material qualification testing, how many batches do you include for developing specification limits and control limits?
Every batch
Every other batch
20 batches
17.
Please describe your experience with dry spot formation during the VARTM process:
18.
If encountered, please list any thoughts on what causes this problem or how to reduce this problem:
