Advanced General Aviation Transport Experiments

Transcription

1 Advanced General Aviation Transport Experiments B-Basis Design Allowables for Wet Layup / Field Repair Fiber Reinforced Composite Material Systems 3K Plain Weave Carbon Cloth / MGS 418 AGATE-WP August 2001 J. Tomblin, J. McKenna, Y. Ng, K. S. Raju National Institute for Aviation Research Wichita State University Wichita, KS

2 TABLE OF CONTENTS 1.0 INTRODUCTION 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 LANCAIR 3K PW CARBON/ MGS 418 WET LAY-UP PROPERTIES Material Documentation by Material Batch Process Specification LANCAIR 3K PW CARBON / MGS 418 LAMINA PROPERTIES Test Results Summary Individual Test Summaries Tension, 2-axis Compression, 2-axis Shear, 12 axis Shear, 13 axis Shear, 13 axis Bearing Strength Individual Test Charts Tension, 2-axis Compression, 2-axis Shear, 12 axis Shear, 13 axis Raw Data Raw Data Spreadsheets and Scatter Charts Fluid Sensitivity Raw Data Spreadsheets and Scatter Charts

3 3.2.3 Representative Shear Stress-Strain Curve Statistical Results Plot by Condition Plot of Pooled Data Moisture Conditioning History Charts DMA Results TESTING AND REPORTING COMMENTS APPENDIX A. DATES OF PANEL MANUFACTURE AND COPY OF FAA FORM

4 1.0 INTRODUCTION 1.1 Scope The Advanced General Aviation Transport Experiments (AGATE) consortium is an industry-university-government partnership initiated by NASA to create the technological basis for revitalization of the United States general aviation industry. It was founded in 1994 to develop affordable new technology as well as the industrial standards and certification methods for composite airframe, cockpit, flight systems and airspace infrastructure for Federal Aviation Regulations (FAR) Part 23 aircraft. The composite material properties contained within the document were generated under Work Package 3: Integrated Design and Manufacturing Methods. Although AGATE was focused towards the small general aviation aircraft (Part 23), the test methods and results contained in this document are consistent with MIL-HDBK-17-1E,2D,3E - 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) as part of the AGATE effort. 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. 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. 4

5 1.2 Symbols Used 21 t c E 2 t E 2 su F 12 su F 13 cu F 2 tu F 2 s G 12 Poisson s ratio, tension relating contraction in the 1 direction as a result of extension in the 2 direction micro-strain compressive modulus, transverse tensile modulus, transverse in plane shear strength apparent interlaminar shear strength compressive strength, transverse tensile strength, transverse in plane shear modulus Superscripts bu c cu s su t tu bearing ultimate compression compression ultimate shear shear ultimate tension tension ultimate Subscripts 1 1 axis; longitudinal 2 2 axis; transverse (parallel to fill direction of reinforcement) 12 in plane shear 13 interlaminar shear (apparent) 5

6 1.3 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 C/Ep Carbon/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

7 1.4 References ASTM Standards D Tensile Properties of Polymer Matrix Composite Materials D Shear Properties of Composite Materials by the V-Notched Beam Method D Apparent Interlaminar Shear Strength of Parallel Fiber Composites by Short Beam Method D Density and Specific Gravity (Relative Density) of Plastics by Displacement D Ignition Loss of Cured Reinforced Plastics D Void Content of Reinforced Plastics D Compressive Properties of Rigid Plastics D Standard Test Method for Bearing Strength of Plastics SACMA Standards SRM 1-94 SRM 8-94 SRM 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-00/47: Material Qualification and Equivalency for Polymer Matrix Composite Material Systems, J.S. Tomblin, Y.C. Ng and K.S. Raju, MIL-HDBK-17 1E, 2D, 3E Military Handbook for Polymer Matrix Composites PACUSA Lancair Document No: AX Rev. B1, Initial Material Qualification of MGS 418 Resin System with 7781 Glass Fabric and Plain Weave Carbon Cloth for Structural Wet Layup Epoxy Laminates, February

8 1.5 Methodology 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 X represents the required material batch letter defined as: material containing 3K Plain Weave Carbon from one mill roll, impregnated with one batch of resin in one continuous manufacturing operation with traceability to all components. and the # represents the required number of replicates for that batch. For example, A6, B6, C6 refers to three material batches A, B, and C; with six specimens per batch for a total requirement of 18 test specimens. The minimum sample requirements are shown, but more samples may have been tested. 8

9 Table 1.5.1: Test Matrix and Standards Used TEST METHOD 90 o (fill) Tension ASTM D Strength 90 o (fill) Tension ASTM D Modulus and Strength 90 o (fill) Compression SACMA SRM 1-94 Strength 90 o (fill) Compression SACMA SRM 1-94 Modulus In-Plane Shear Strength ASTM D In-Plane Shear Modulus ASTM D and Strength Short Beam Shear ASTM D NO. OF REPLICATES PER TEST CONDITION CTD 2,6 RTD 1,3,6 ETW 1,4 ETD 5,6 B4 B2 B6 B2 B4 B2 A4, B4, C4 A2, B2, C2 A6, B6, C6 A2, B2, C2 A4, B4, C4 A2, B2, C2 A4, B4, C4, D4 A2, B2, C2, D2 A6, B6, C6, D6 A2, B2, C2, D2 A4, B4, C4, D4 A2, B2, C2, D2 -- A6, B6, C6, D6 Fiber Volume ASTM D One sample per panel Resin Volume ASTM D One sample per panel Void Content 7 ASTM D One sample per panel Cured Neat Resin Density Glass Transition Temperature --- SACMA SRM A4, B4, C4 A2, B2, C2 A6, B6, C6 A2, B2, C2 A4, B4, C4 A2, B2, C Supplied by manufacturer for material 3 dry, 3 wet per material batch Notes : 1 Per the current test plan, panels are Batch D. Per previous revisions, these panels are Batch E. All tested specimens and data sets that are labeled Batch E are equivalent to Batch D. 2 CTD: One batch of material tested (test temperature = o F, moisture content = as fabricated, soak time at 65 was 3 min.) 3 RTD: Three batches of material tested (test temperature = o F, moisture content = as fabricated) 4 ETW: Four batches of material tested (test temperature = o F, moisture content = equilibrium per section 1.5.2, soak time at 180 was 60 sec.) 5 ETD: Three batches of material tested (test temperature = o F, moisture content = as fabricated, soak time at 180 was 3 min.) 6 Dry specimens are as fabricated specimens that have been maintained at ambient conditions in an environmentally controlled laboratory. 7 The generic 418 resin density value (1.2 g/cc) is used to calculate void content and does not take into account the effects of the resin/hardener mix ratio or the cure cycle. 9

10 1.5.2 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 145 ± 5 F until an equilibrium moisture weight gain of traveler, or witness coupons (1 x 1 x specimen thickness) was achieved. ASTM D5229 and SACMA SRM 11 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 0.05% for two consecutive readings within a span of 7 ± 0.5 days and was 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 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 14 days until mechanical testing. Strain gauged specimens were removed from the controlled environment for a maximum of 2 hours for application of gages in ambient laboratory conditions Fluid Sensitivity Screening Although epoxy-based materials historically have not been shown to be sensitive to fluids other than water or moisture, the influence of some fluids other than water or moisture on the mechanical properties were characterized. These fluids fell into two exposure classifications. The first class was considered to be in contact with the material for an extended period of time, and the second class was considered to be wiped on and off (or evaporate) with relatively short exposure times. To assess the degree of sensitivity of fluids other than water or moisture, Table shows the fluids which were used in this qualification plan. 10

11 Table 1.5.2: Fluid Types Used for Sensitivity Studies Fluid Type Jet Fuel (JP-4) Hydraulic Fluid (Tri-N-butyl phosphate ester) Solvent (Methyl Ethyl Ketone) Specification MIL-T-5624 MIL-H-5606G Laboratory Grade Exposure Classification Extended Period Extended Period Wipe On and Off To assess the influence of various fluids types, a test method sensitive to matrix degradation was used as an indicator of fluid sensitivity and compared to the unexposed results at both room temperature dry and elevated temperature dry conditions. Table describes the fluid sensitivity-testing matrix with respect to the fluids defined in Table Engineering judgment and statistical tests were used to assess the degree of material degradation. The results of this screening are included following the data sheets in section Table 1.5.3: Material Qualification Program for Fluid Resistance Fluid Type Test Method Test Temp. ( o F) Exposure 1 Number of Replicates 2 Jet Fuel JP-4 ASTM D See note 4 5 Hydraulic Fluid ASTM D See note 5 5 Solvent (MEK) ASTM D Ambient See note 5 5 Notes : 1 Soaking in fluid at ambient temperature (immersion). 2 Only a single batch of material is required. 3 Shear strength only. 4 Immersion duration = 500 hours 50 hours 5 Immersion duration = 60 to 90 minutes 11

12 1.5.4 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: 90 (fill) Tension Strength and Modulus 90 (fill) Compression Strength and Modulus The normalization procedure was adopted from MIL-HDBK-17-1E, section 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 0.45 to 0.65 fiber volume fraction range. Additional information is detailed in Material Qualification and Equivalency for Polymer Matrix Composite Material Systems. For all 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 12

13 1.5.5 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 5.3 of FAA Document DOT/FAA/AR- 00/47: Material Qualification and Equivalency for Polymer Matrix Composite Material Systems 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 shows an example material performance envelope using B-basis values. 13

14 CTD B-Basis Strength Values (ksi) Material Performance Envelope RTD ETD ETW Temperature ( o F) Figure Material performance envelope. Since each specific aircraft application of the qualified material may have different Maximum 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 14

15 where B MOL = new application basis value interpolated to T MOL 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 150 o F, Figure 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 1.5.1), the interpolated basis values at 150 o F become 15

16 ETD : B MOL = ksi ETW : B MOL = ksi 120 Actual Basis Value Estimated Value 100 CTD RTD B-Basis Strength Values (ksi) RTW ETD ETW Temperature ( o F) Figure Example of 150 o F interpolation for B-basis values. 16

17 2.0 LANCAIR 3K PW CARBON/ MGS 418 WET LAY-UP PROPERTIES 17

18 2.1 Material Documentation by Material Batch Wet Lay-up Documentation Manufacturer & Product ID: PAC Material Identification (weave, form, class, etc.): Impregnation Method: Wet Layup Resin : Hardener Ratio 100 : 37 by wt. 100 : 40 by wt. 100 : 43 by wt. 100 : 40 by wt. Batch (Lot) ID as labeled on samples A B C D 1 E Date of Manufacture (Post Cure) 6/98 6/98 6/98 6/98 Expiration Date N/A N/A N/A N/A Resin Content [wt %] 38% 38% 38% 46% Reinforcement Areal Weight & Test Method Resin Flow & Test Conditions Gel Time & Test Conditions Volatile Content Reinforcement Documentation See Fabric Info. Not Tested Not Tested Fiber/Fabric Manufacturer & Product ID: Plain-weave, 3K T-300 fibers Precursor Type: Unknown Nominal Filament Count: 3K Fabric with 12.2 ends & 12.4 picks Finish/Sizing Type and %: Unknown Nominal tow or yarn count/inch: Above Twist: Fabric Batch or Lot # Multiple 2 Multiple Multiple Multiple Date of Manufacture Multiple 2 Multiple Multiple Multiple Average Fiber Density per Lot & Test Method g/cc g/cc g/cc g/cc Matrix Documentation Resin Manufacturer & Product ID: MGS 418 Matrix Batch or Lot # (Resin) or No Records Unknown Matrix Batch or Lot # (Hardener) or No Records Date of Manufacture Unknown Unknown Unknown Unknown Average Neat Resin Density by Lot & Test Method No Records No Certs. No Certs. No Certs. Note: Test Methods used to determine resin content, reinforced areal weight, resin flow, gel time, and volatile content are defined in PAC USA Lancair AX Rev. B1 specification 1 Per current test plan, panels are Batch D. Per previous revisions, these are Batch E. 2 Assumed, but no records. 18

19 2.2 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 processing procedures are excerpts from PACUSA Lancair Document No: AX Rev. B1, "Initial Material Qualification of MGS 418 Resin System with 7781 Glass Fabric and Plain Weave Carbon Cloth for Structural Wet Layup Epoxy Laminates". All test specimens were cured per this specification by Pacific Aviation Composites. Panel Processing Parameters Table defines how the four batches of panels were processed. Definitions for each of the process variables follow the table. Table 2.2.1: Panel Processing Panel Batch Resin Content Fiber Content (by weight %) Curing Agent Content Cure Cycle Glass Carbon A Nominal Minimum Minimum B Nominal Nominal Nominal C Nominal Maximum Over D Maximum Nominal Nominal E Nominal Nominal Nominal Panel Batch A... Minimum curing agent content in combination with the minimum cure cycle and nominal resin content. Panel Batch B... Nominal curing agent content in combination with the nominal cure cycle and nominal resin content. Panel Batch C... Maximum curing agent content in combination with an over cure cycle and nominal resin content. Panel Batch D... Nominal curing agent content in combination with the nominal cure cycle and maximum resin content. Panel Batch E... Nominal curing agent content in combination with the nominal cure cycle and the nominal resin content, using glass fabric from full-scale fatigue test. 19

20 Nominal Resin Content... Layup with 62 1% glass fiber by weight and 53 1% carbon fiber by weight. Max Resin Content... Layup with 54 1% glass fiber by weight and 45 1% carbon fiber by weight. Curing Agent Content... Nominal, Minimum and Maximum in Table Minimum Cure Cycle... Nominal cure cycle temperature minus 30 F with nominal cure time minus 1 hour. Over Cure Cycle... Nominal cure cycle temperature plus 30 F plus three extra nominal cure cycle times. Table 2.1.2: Curing Agent Content Minimum curing agent content Nominal curing agent content Maximum curing agent content 100:37 by weight 100:40 by weight 100:43 by weight Oven Cure Procedure Nominal Cure Cycle 1 : a. Pre-cure undisturbed at room temperature until resin is set, defined as does not stick to the finger when touched. b. Install the assembly in a cool oven (temperatures less than 100 o F). Verify the functioning of the thermocouple recording equipment before initiating the cure. c. Perform post-cure to the following steps: Ramp from ambient to F over a period of minutes (2 hrs). Hold at F for 240 (+10, -0) minutes (4 hrs.). Ramp to 200 ± 10 o F over a period of minutes (2 hrs.). Hold at 200 ± 10 o F for 360 (+10, -0) minutes (6 hrs.). Ramp down below 170 F at a rate not to exceed 10 F per minute before removing the cured panel from the oven. Minimum Cure Cycle 1 : a. Pre-cure undisturbed at room temperature until resin is set, defined as does not stick to the finger when touched. b. Install the assembly in a cool oven (temperatures less than 100 o F). Verify the functioning of the thermocouple recording equipment before initiating the cure. 1 All temperatures are oven temperature. 20

21 c. Perform post-cure to the following steps: Ramp from ambient to F over a period of minutes (2 hrs.). Hold at F for 210 (+10, -0) minutes (3-1/2 hrs.). Ramp to 170 ± 10 o F over a period of minutes (2 hrs.). Hold at 170 ± 10 o F for 330 (+10, -0) minutes (5-1/2 hrs.). Ramp down below 140 F at a rate not to exceed 10 F per minute before removing the cured panel from the oven. Over Cure Cycle 1 : a. Pre-cure undisturbed at room temperature until resin is set, defined as does not stick to the finger when touched. b. Install the assembly in a cool oven (temperatures less than 100 o F). Verify the functioning of the thermocouple recording equipment before initiating the cure. c. Perform post-cure to the following steps: Ramp from ambient to F over a period of minutes (2 hrs.). Hold at F for minutes (14 hrs.). Ramp to 230 ± 10 o F over a period of minutes (2 hrs.). Hold at 230 ± 10 o F for minutes (24 hrs). Ramp down below 170 F at a rate not to exceed 10 F per minute before removing the cured panel from the oven. 21

22 3.0 LANCAIR 3K PW CARBON / MGS 418 LAMINA PROPERTIES 22

23 3.1 Test Results 23

24 3.1.1 Summary MATERIAL: PAC 3K Plain Weave Carbon / MGS 418 Wet Layup 3K PW Carbon/MGS 418 FIBER: 3KT-300 PW Carbon Fibers RESIN: MGS 418 Summary T g (dry): F T g (wet): F T g METHOD: DMA (SRM 18-94) PROCESSING: Vacuum bag cure (22+ in. Hg.): F for hours Date of fiber manufacture Multiple Date of testing 4/12/99 10/4/99 Date of resin manufacture Unknown Date of data submittal 10/8/99 Date of composite manufacture 6/98 Date of analysis 4/13/99 10/5/99 LAMINA MECHANICAL PROPERTY Data Reported as: Measured (Normalized by CPT= in) F 2 tu (ksi) (60.49) CTD RTD ETD ETW B-Basis Mean B-Basis Mean B-Basis Mean B-Basis Mean (65.86) E 2 t (Msi) (7.03) (56.99) (62.06) (6.91) (58.66) (63.87) (6.92) (57.89) (63.03) (6.90) 21 tu (ksi) F 2 cu (ksi) (61.52) (71.55) E 2 c (Msi) (6.45) (53.44) (62.15) (6.25) (39.07) (45.43) (6.14) (32.62) (37.93) (5.92) F 12 su (ksi) G 12 s (Msi) F 13 su** (ksi) ** Apparent interlaminar shear strength 24

25 3.1.2 Individual Test Summaries 25

26 Tension, 2-axis Material: Lancair 3K Plain Weave Carbon / MGS 418 Wet Layup Resin content: wt% Comp. density: g/cc Fiber volume: vol% Void content: 4.5 to 7.2 % Ply thickness: in. Ply range: 12 plies Tension, 2-axis C/Ep 3K PW Carbon / MGS 418 [0] 12 Test method: D Modulus calculation: N/A Normalized by: in. ply thickness CTD (B) RTD (A) ETD (G) ETW(F) Test Temperature [ F] Moisture Conditioning dry dry dry equilibrium Equilibrium at T, RH as fabricated as fabricated as fabricated 145 F, 85 % Source code MWUXXXXB MWUXXXXXA MWUXXXXG MWUXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F 2 tu (ksi) B-value A-value E 2 t (Msi) 21 t No. Specimens No. Batches Mean Minimum Maximum C.V.(%) No. Specimens No. Batches Mean No. Specimens No. Batches

27 Compression, 2-axis Material: Lancair 3K Plain Weave Carbon / MGS 418 Wet Layup Resin content: wt% Comp. density: g/cc Fiber volume: vol% Void content: 4.5 to 6.6 % Ply thickness: in. Ply range: 12 plies Compression, 2-axis C/Ep 3K PW Carbon / MGS [0] 12 Test method: D Modulus calculation: N/A Normalized by: N/A CTD (B) RTD (A) ETD (G) ETW(F) Test Temperature [ F] Moisture Conditioning dry dry dry equilibrium Equilibrium at T, RH as fabricated as fabricated as fabricated 145 F, 85 % Source code MWWXXXXB MWWXXXXA MWWXXXXG MWWXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F 2 cu (ksi) B-value A-value c E 2 (Msi) No. Specimens No. Batches Mean Minimum Maximum C.V.(%) No. Specimens No. Batches

28 Shear, 12 axis Material: Lancair 3K Plain Weave Carbon / MGS 418 Wet Layup Resin content: wt% Comp. density: g/cc Fiber volume: vol% Void content: 5.2 to 6.6% Ply thickness: in. Ply range: 12 plies Shear, 12-axis C/Ep 3K PW Carbon / MGS 418 [0/90] 6 Test method: D Modulus calculation: N/A Normalized by: N/A CTD (B) RTD (A) ETD (G) ETW(F) Test Temperature [ F] Moisture Conditioning dry dry dry equilibrium Equilibrium at T, RH as fabricated as fabricated as fabricated 145 F, 85 % Source code MWNXXXXB MWNXXXXA MWNXXXXG MWNXXXXF Normalized Measured Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean Minimum Maximum C.V.(%) F 12 su (ksi) B-value A-value G 12 s (Msi) No. Specimens No. Batches Mean Minimum Maximum C.V.(%) No. Specimens No. Batches

29 Shear, 13 axis Material: Lancair 3K Plain Weave Carbon / MGS 418 Wet Layup Resin content: wt% Comp. density: g/cc Fiber volume: vol% Void content: 4.5 to 6.4 % Ply thickness: in. Ply range: 12 plies Shear, 13-axis C/Ep 3K PW Carbon / MGS 418 [0] 12 Test method: D2344 Modulus calculation: N/A Normalized by: in. ply thickness RTD (A) Test Temperature [ F] Moisture Conditioning Equilibrium at T, RH Source code 75 dry as fabricated MWQXXXX Normalized Measured A Normalized Measured Normalized Measured Normalized Measured Normalized Measured Mean 8.79 Minimum 8.27 Maximum 9.43 C.V.(%) 4.09 su F 13 (ksi) B-value 8.15 A-value 7.69 No. Specimens No. Batches 30 4 NOTE: 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. 29

30 Bearing Strength Material: Lancair 3K Plain Weave Carbon / MGS 418 Wet Layup Resin content: wt% Comp. density: g/cc Fiber volume: % Void content: 2.8 to 7.9 % Bearing Strength C/Ep Lancair 3K Plain Weave Carbon/MGS 418 Wet Layup Test method: ASTM D Type of bearing test: Double Shear Pin Bearing Fastener Type: Hardened Steel Pin Torque: N/A Normalized by: Not normalized CTD RTD ETD ETW Test Temperature [ F] Moisture Conditioning dry dry dry equilibrium Equilibrium at T, RH as fabricated as fabricated as fabricated 145F, 85% Source code MW#XXXXB MW#XXXXA MW#XXXXG MW#XXXXF Diameter[in] Mean F bu Minimum (ksi) Maximum [0/45/0] s (6 plies) C.V.(%) t ply: in. Failure Mode Bearing Bearing Bearing Bearing Bearing Bearing Bearing Bearing No. Specimens No. Batches Mean F bu Minimum (ksi) Maximum [(0/45) 5] s (20 plies) C.V.(%) t ply: in. Failure Mode Bearing Bearing Bearing Bearing Bearing Bearing Bearing Bearing No. Specimens No. Batches

31 3.1.3 Individual Test Charts 31

32 Tension, 2-axis 90 Tension-- 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 180 dry and wet data have been staggered for clarity. 32

33 Compression, 2-axis 90 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 180 dry and wet data have been staggered for clarity. 33

34 Shear, 12 axis In-Plane Shear -- Measured 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 180 dry and wet data have been staggered for clarity. 34

35 Shear, 13 axis 20 Apparent Interlaminar Shear -- Measured Strength 15 Strength (ksi) 10 5 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. 35

36 3.2 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. M W U F 1 st Character: Fabricator M designates Lancair 2 nd Character: Material System W designates 3K PW Carbon / MGS rd Character: Test Type U designates 90 Tension Strength and Modulus, other test types will be clearly labeled at the top of each sheet 4 th Character: Material Batch ID See Table 2.1 for Lancair Batch ID Documentation. 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 samples numbered 1,2 9,A,B,. 8 th Character: Test Condition A --- RTD B --- CTD F --- ETW G --- ETD See Table for condition parameters. 36

37 3.2.1 Raw Data Spreadsheets and Scatter Charts 37

38 90 Tension-- (RTD) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] MWUA1X6A A MWUA1X7A A MWUA1X8A A MWUA3X5A A MWUA3X6A A MWUA3X7A A MWUB2X1A B MWUB2X2A B MWUB2X3A B MWUB2X4A B MWUB2X5A B MWUB2X6A B MWUC1X6A C MWUC1X7A C MWUC1X8A C MWUC4X5A C MWUC4X6A C MWUC4X7A C 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 90 Tension -- (RTD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Tension -- (RTD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 39

40 90 Tension-- (CTD) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] MWUB1X1B B MWUB1X2B B MWUB1X3B B MWUB1X4B B MWUB1X5B B MWUB1X6B B 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

41 90 Tension -- (CTD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Tension -- (CTD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 41

42 90 Tension-- (ETW) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] MWUA1X1F A MWUA1X2F A MWUA1X3F A MWUA1X4F A MWUA1X5F A MWUA3X1F A MWUA3X2F A MWUA3X3F A MWUA3X4F A MWUB3X1F B MWUB3X2F B MWUB3X3F B MWUB3X4F B MWUB3X5F B MWUB3X6F B MWUB3X7F B MWUB3X8F B MWUB3X9F B MWUC4X1F C MWUC4X2F C MWUC4X3F C MWUC4X4F C MWUC1X1F C MWUC1X2F C MWUC1X3F C MWUC1X4F C MWUC1X5F C MWUE1X2F E MWUE1X3F E MWUE1X4F E MWUE1X5F E MWUE1X6F E MWUE1X7F E MWUE1X8F E 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

43 90 Tension -- (ETW) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Tension -- (ETW) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 43

44 90 Tension-- (ETD) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Poisson's Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Ratio Thickn. [in] Laminate [in] [ksi] [Msi] MWUA2X1G A MWUA2X2G A MWUA2X3G A MWUA2X4G A MWUA2X5G A MWUA2X6G A MWUA2X7G A MWUB4X1G B MWUB4X2G B MWUB4X3G B MWUB4X4G B MWUB4X5G B MWUB4X6G B MWUC2X1G C MWUC2X2G C MWUC2X3G C MWUC2X4G C MWUC2X5G C MWUC2X6G C 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

45 90 Tension -- (ETD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Tension -- (ETD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 45

46 90 Compression-- (RTD) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] MWWA121A A MWWA122A A MWWA123A A MWWA124A A MWWA125A A MWWA126A A MWWA127A A MWZA3X6A A MWZA3X7A A MWWB121A B MWWB122A B MWWB123A B MWWB124A B MWWB125A B MWWB126A B MWWB127A B MWZB2X8A B MWZB2X9A B MWWC121A C MWWC122A C MWWC123A C MWWC124A C MWWC125A C MWWC126A C MWZC4X6A C MWZC4X7A C 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

47 90 Compression -- (RTD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Compression Strength [ksi] 90 Compression -- (RTD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Compression Modulus [Msi] 47

48 90 Compression-- (CTD) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] MWWB411B B MWWB412B B MWWB413B B MWWB414B B MWWB415B B MWWB416B B MWZB2X5B B MWZB2X6B B Average Average norm Standard Dev Standard Dev. norm Coeff. of Var. [%] Coeff. of Var. [%] norm Min Min Max Max Number of Spec. 6 2 Number of Spec

49 90 Compression -- (CTD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Compression -- (CTD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 49

50 90 Compression-- (ETW) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] MWWA111F A MWWA112F A MWWA113F A MWWA114F A MWWA115F A MWWA116F A MWWA117F A MWWA118F A MWZA3X1F A MWZA3X2F A MWWB111F B MWWB112F B MWWB113F B MWWB114F B MWWB115F B MWWB116F B MWWB117F B MWWB118F B MWZB2X1F B MWZB2X2F B MWWC111F C MWWC112F C MWWC113F C MWWC114F C MWWC115F C MWWC116F C MWWC117F C MWWC118F C MWZC4X1F C MWZC4X2F C MWWE1X1F E MWWE1X2F E MWWE1X3F E MWWE1X4F E MWWE1X5F E MWWE1X6F E MWWE1X7F E MWWE1X8F E MWZE211F E MWZE212F E 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

51 90 Compression -- (ETW) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Compression-- (ETW) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 51

52 90 Compression-- (ETD) Strength & Modulus normalizing t ply [in] Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Strength norm Modulus norm Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] [ksi] [Msi] MWWA119G A MWWA11AG A MWWA128G A MWWA129G A MWWA12AG A MWWA12BG A MWZA3X9G A MWZA3XAG A MWWB128G B MWWB129G B MWWB12AG B MWWB119G B MWWB11AG B MWWB11BG B MWZB2XBG B MWZB2XCG B MWWC119G C MWWC11AG C MWWC11BG C MWWC11CG C MWWC128G C MWWC129G C MWZC4X9G C MWZC4XAG C 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

53 90 Compression -- (ETD) Normalized Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Strength [ksi] 90 Compression-- (ETD) Normalized Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Tension Modulus [Msi] 53

54 In-Plane Shear -- (RTD) Strength & Modulus Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] MWNA121A A MWNA122A A MWNA123A A MWNA124A A MWNA125A A MWNA126A A MWNA127A A MWNB111A B MWNB112A B MWNB113A B MWNB114A B MWNB115A B MWNB129A B MWNB12AA B MWNC131A C MWNC132A C MWNC133A C MWNC134A C MWNC135A C MWNC136A C MWNC137A C Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec

55 In-Plane Shear -- (RTD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Strength [ksi] In-Plane Shear -- (RTD) Measured Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Modulus [Msi] 55

56 In-Plane Shear -- (CTD) Strength & Modulus Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Batch# Batch # [ksi] [Msi] Thickn. [in] Laminate [in] MWNB131B B MWNB132B B MWNB133B B MWNB134B B MWNB135B B MWNB136B B MWNB137B B Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec

57 In-Plane Shear -- (CTD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Strength [ksi] In-Plane Shear -- (CTD) Measured Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Modulus [Msi] 57

58 In-Plane Shear -- (ETW) Strength & Modulus Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] MWNA111F A MWNA112F A MWNA113F A MWNA114F A MWNA115F A MWNA116F A MWNA117F A MWNA118F A MWNA119F A MWNB121F B MWNB122F B MWNB123F B MWNB124F B MWNB125F B MWNB126F B MWNB127F B MWNB128F B MWNC111F C MWNC112F C MWNC113F C MWNC114F C MWNC115F C MWNC116F C MWNC117F C MWNC118F C MWNC119F C MWNE111F E MWNE112F E MWNE113F E MWNE114F E MWNE115F E MWNE116F E MWNE117F E MWNE118F E MWNE119F E Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec

59 In-Plane Shear -- (ETW) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Strength [ksi] In-Plane Shear -- (ETW) Measured Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Modulus [Msi] 59

60 In-Plane Shear -- (ETD) Strength & Modulus Specimen Panel ASAP Strength Modulus Avg. Specimen # Plies in Avg. t ply Number Batch # Batch # [ksi] [Msi] Thickn. [in] Laminate [in] MWNA131G A MWNA132G A MWNA133G A MWNA134G A MWNA135G A MWNA136G A MWNA137G A MWNB151G B MWNB152G B MWNB153G B MWNB154G B MWNB155G B MWNB156G B MWNB157G B MWNC141G C MWNC142G C MWNC143G C MWNC144G C MWNC145G C MWNC146G C MWNC147G C Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec

61 In-Plane Shear -- (ETD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # In-Plane Shear Strength [ksi] In-Plane Shear -- (ETD) Measured Modulus Pooled Average = [Msi] Pooled Standard Deviation = [Msi] Pooled Coeff. of Variation =4.253[%] 4 ASAP Batch # In-Plane Shear Modulus [Msi] 61

62 Apparent Interlaminar Shear -- (RTD) Strength & Modulus Specimen Panel ASAP Strength Avg. Specimen # Plies in Avg. t ply Number Batch # Batch # [ksi] Thickn. [in] Laminate [in] MWQA111A A MWQA112A A MWQA113A A MWQA114A A MWQA115A A MWQA116A A MWQA117A A MWQA118A A MWQB1X1A B MWQB1X2A B MWQB1X3A B MWQB1X4A B MWQB1X5A B MWQB1X6A B MWQB1X7A B MWQB1X8A B MWQC111A C MWQC112A C MWQC113A C MWQC114A C MWQC115A C MWQC116A C MWQC117A C MWQE111A E MWQE112A E MWQE113A E MWQE115A E MWQE116A E MWQE117A E MWQE118A E Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec

63 Apparent Interlaminar Shear -- (RTD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] 4 ASAP Batch # Apparent Interlaminar Shear Strength [ksi] 63

64 Bearing Strength [45/0/45] s t=0.060",d=0.1875" Condition Specimen Panel Strength Avg. Specimen # Plies in Avg. tply Number Batch # [ksi] Thickn. [in] laminate [in] MW1B211B B Average MW1B212B B Standard Dev. CTD MW1B213B B Coeff. of Var. [%] MW1B214B B Min. MW1B215B B Max. MW1B216B B Number of Spec. MW1B231A B Average MW1B232A B Standard Dev. RTD MW1B233A B Coeff. of Var. [%] MW1B234A B Min. MW1B235A B Max. MW1B236A B Number of Spec. MW1B221F B MW1B223F B MW1B224F B Average ETW MW1B225F B Standard Dev. MW1B226F B Coeff. of Var. [%] MW1B227F B Min. MW1B228F B Max. MW1B229F B Number of Spec. MW1B111G B Average MW1B112G B Standard Dev. ETD MW1B113G B Coeff. of Var. [%] MW1B114G B Min. MW1B115G B Max. MW1B117G B Number of Spec. 64

65 Bearing Strength [45/0/45]s t=0.060",d=0.1875" ETD4 ETW3 RTD2 CTD Bearing Strength [ksi] 65

66 Bearing Strength [45/0/45] s t=0.060",d=0.250" Condition Specimen Panel Strength Avg. Specimen # Plies in Avg. tply Number Batch # [ksi] Thickn. [in] laminate [in] MW2B221B B MW2B222B B Average MW2B223B B Standard Dev. CTD MW2B224B B Coeff. of Var. [%] MW2B225B B Min. MW2B226B B Max. MW2B227B B Number of Spec. MW2B111A B Average MW2B112A B Standard Dev. RTD MW2B113A B Coeff. of Var. [%] MW2B115A B Min. MW2B116A B Max. MW2B117A B Number of Spec. MW2B211F B MW2B212F B MW2B213F B Average ETW MW2B214F B Standard Dev. MW2B215F B Coeff. of Var. [%] MW2B216F B Min. MW2B217F B Max. MW2B218F B Number of Spec. MW2B232G B Average MW2B233G B Standard Dev. ETD MW2B234G B Coeff. of Var. [%] MW2B235G B Min. MW2B236G B Max. MW2B237G B Number of Spec. 66

67 Bearing Strength [45/0/45]s t=0.060",d=0.250" ETD4 ETW3 RTD2 CTD Bearing Strength [ksi] 67

68 Bearing Strength [(0/45) 5 ] s t=0.200",d=0.250" Condition Specimen Panel Strength Avg. Specimen # Plies in Avg. tply Number Batch # [ksi] Thickn. [in] laminate [in] MW3B311B B Average MW3B312B B Standard Dev. CTD MW3B313B B Coeff. of Var. [%] MW3B314B B Min. MW3B315B B Max. MW3B316B B Number of Spec. MW3B331A B Average MW3B332A B Standard Dev. RTD MW3B333A B Coeff. of Var. [%] MW3B334A B Min. MW3B335A B Max. MW3B336A B Number of Spec. MW3B111F B MW3B112F B MW3B113F B Average ETW MW3B114F B Standard Dev. MW3B115F B Coeff. of Var. [%] MW3B116F B Min. MW3B117F B Max. MW3B118F B Number of Spec. MW3B321G B Average MW3B322G B Standard Dev. ETD MW3B323G B Coeff. of Var. [%] MW3B324G B Min. MW3B325G B Max. MW3B326G B Number of Spec. 68

69 Bearing Strength [(0/45) 5 ]s t=0.200",d=0.250" ETD4 ETW3 RTD2 CTD Bearing Strength [ksi] 69

70 Bearing Strength [(0/45) 5 ] s t=0.200",d=0.375" Condition Specimen Panel Strength Avg. Specimen # Plies in Avg. tply Number Batch # [ksi] Thickn. [in] laminate [in] MW4B211B B Average MW4B212B B Standard Dev. CTD MW4B213B B Coeff. of Var. [%] MW4B214B B Min. MW4B215B B Max. MW4B216B B Number of Spec. MW4B131A B Average MW4B132A B Standard Dev. RTD MW4B133A B Coeff. of Var. [%] MW4B134A B Min. MW4B135A B Max. MW4B136A B Number of Spec. MW4B111F B MW4B112F B MW4B113F B Average ETW MW4B114F B Standard Dev. MW4B115F B Coeff. of Var. [%] MW4B116F B Min. MW4B122F B Max. MW4B123F B Number of Spec. MW4B124G B Average MW4B125G B Standard Dev. ETD MW4B126G B Coeff. of Var. [%] MW4B217G B Min. MW4B218G B Max. MW4B219G B Number of Spec. 70

71 Bearing Strength [(0/45) 5 ]s t=0.200",d=0.375" ETD4 ETW3 RTD2 CTD Bearing Strength [ksi] 71

72 3.2.2 Fluid Sensitivity Raw Data Spreadsheets and Scatter Charts 72

73 In-Plane Shear -- (MEK - RTD) Strength & Modulus Specimen Batch Strength Avg. Specimen # Plies in Avg. t ply Number Number [ksi] Thickn. [in] Laminate [in] MWNC11AT C MWNC138T C MWNC148T C MWNC149T C MWNC14AT C Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec. 5 In-Plane Shear -- (MEK - RTD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] C3 Batch # B2 A In-Plane Shear Strength [ksi] 73

74 In-Plane Shear -- (JP-4 JET FUEL - ETD) Strength & Modulus Specimen Batch Strength Avg. Specimen # Plies in Avg. t ply Number Number [ksi] Thickn. [in] Laminate [in] MWNA128R A MWNA129R A MWNA12AR A MWNA138R A MWNA139R A MWNA13AR A Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec. 6 In-Plane Shear -- (JP-4 JET FUEL - ETD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] C3 Batch # B2 A In-Plane Shear Strength [ksi] 74

75 In-Plane Shear -- (Hydraulic Fluid - ETD) Strength & Modulus Specimen Batch Strength Avg. Specimen # Plies in Avg. t ply Number Number [ksi] Thickn. [in] Laminate [in] MWNB138V B MWNB139V B MWNB13AV B MWNB158V B MWNB159V B MWNB15AV B Average Standard Dev Coeff. of Var. [%] Min Min Max Max Number of Spec. 6 In-Plane Shear -- (Hydraulic Fluid - ETD) Measured Strength Pooled Average = [ksi] Pooled Standard Deviation = [ksi] Pooled Coeff. of Variation = [%] C 3 Batch # B 2 A In-Plane Shear Strength [ksi] 75

76 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 1% after exposure to MEK. However it remained 81% higher than water exposure in ETW conditions. Average In-Plane Shear Strength with Fluid (ksi) JP-4 JET FUEL (ETD) 9.48 Same Environment In-Plane Shear Strength without Fluid (ksi) (ETD) 9.65 Worst Case Environment In-Plane Shear Strength (ksi) (ETW) 8.39 The ETD average in-plane shear strength was reduced by 2% after exposure to JP-4 Jet Fuel. However it remained 13% 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 not reduced after exposure to Hydraulic Fluid

77 3.2.3 Representative Shear Stress-Strain Curve The following shear stress-strain curve is representative of the 3K PW Carbon / MGS 418 Wet Lay-up 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- 17-1E, 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. 77

78 Shear Stress vs. Shear Strain, RTD Shear Stress [psi] y -1 = a + b/x r 2 = a = e-05 b = e Shear Strain [in/in] 78

79 3.3 Statistical Results 79

80 3.3.1 Plot by Condition 80

81 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Lancair CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Tension- MWUXXXXX Measured 81

82 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Lancair CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE In-Plane Shear - MWUXXXXX Normalized 82

83 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Lancair CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Compression - MWWXXXXX Measured 83

84 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Lancair CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Compression - MWWXXXXX Normalized 84

85 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Lancair CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE In-Plane Shear - MWNXXXXX Measured 85

86 DISTRIBUTION OF GROUPED DATA FOR DIFFERENT TEST CONDITIONS PROBABILITY OF SURVIVAL Lancair CTD RTD ETD ETW NO DATA NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE NORMAL CURVE Apparent Interlaminar Shear - MWQXXXXX Measured 86

87 3.3.2 Plot of Pooled Data 87

88 DISTRIBUTION OF POOLED DATA Lancair 90 Tension- MWUXXXXX Measured PROBABILITY OF SURVIVAL NORMALIZED VALUE 88

89 DISTRIBUTION OF POOLED DATA Lancair In-Plane Shear - MWUXXXXX Normalized PROBABILITY OF SURVIVAL NORMALIZED VALUE 89

90 DISTRIBUTION OF POOLED DATA Lancair 90 Compression - MWWXXXXX Measured PROBABILITY OF SURVIVAL NORMALIZED VALUE 90

91 DISTRIBUTION OF POOLED DATA Lancair 90 Compression - MWWXXXXX Normalized PROBABILITY OF SURVIVAL NORMALIZED VALUE 91

92 DISTRIBUTION OF POOLED DATA Lancair In-Plane Shear - MWNXXXXX Measured PROBABILITY OF SURVIVAL NORMALIZED VALUE 92

93 DISTRIBUTION OF POOLED DATA Lancair Apparent Interlaminar Shear - MWQXXXXX Measured PROBABILITY OF SURVIVAL NORMALIZED VALUE 93

94 3.4 Moisture Conditioning History Charts 94

95 % Weight Gain (Total) Conditioning History LANCAIR MWUA1 MWUA3 MWUE1 MWUB3 MWUB3 MWUC1 MWUC Time (days) 0.7 Conditioning History LANCAIR 0.6 % Weight Gain (Total) MWWA1 MWWB1 MWWC1 MWWE Time (days) 95

96 0.6 Conditioning History LANCAIR 0.5 % Weight Gain (Total) MWNA MWNB MWNC MWNE Time (days) 0.7 Conditioning History LANCAIR 0.6 % Weight Gain (Total) MWZE1 MWZA3 MWZC4 MWZB Time (days) 96

97 0.4 Conditioning History LANCAIR 0.3 % Weight Gain (Total) MWB12 MWB22 MWB31 MWB Time (days) 0.4 Conditioning History LANCAIR % Weight Gain (Total) Time (days) MWDA MWDB MWDC MWDE 97

98 3.5 DMA Results 98

99 COMPANY: Lancair MATERIAL SYSTEM: 3K PW Carbon / MGS 418 Wet Layup PROJECT: C1 DMA Results -- Onset Storage Modulus DRY WET As Fabricated Moisture Equilibrium at 85% RH Sample # Tg [ C] Tg [ F] Sample # Tg [ C] Tg [ F] MWDA1D7A MWDA1D1F MWDA1D8A MWDA1D2F MWDA1D9A MWDA1D3F MWDB2D7A MWDB2D1F MWDB2D8A MWDB2D2F MWDB2DAA MWDB2D3F MWDC3D7A MWDC3D1F MWDC3D8A MWDC3D2F MWDC3D9A MWDC3D3F MWDE2D7A MWDE2D1F MWDE2D8A MWDE2D2F MWDE2D9A MWDE2D3F Average [ F] Average [ F] Standard Dev. [ F] 8.70 Standard Dev. [ F] 5.07 Coeff. Of Var. [%] 4.02 Coeff. Of Var. [%] 2.44 DMA Results - Peak Tan Delta DRY WET As Fabricated Moisture Equilibrium at 85% RH Sample # Tg [ C] Tg [ F] Sample # Tg [ C] Tg [ F] MWDA1D7A MWDA1D1F MWDA1D8A MWDA1D2F MWDA1D9A MWDA1D3F MWDB2D7A MWDB2D1F MWDB2D8A MWDB2D2F MWDB2DAA MWDB2D3F MWDC3D7A MWDC3D1F MWDC3D8A MWDC3D2F MWDC3D9A MWDC3D3F MWDE2D7A MWDE2D1F MWDE2D8A MWDE2D2F MWDE2D9A MWDE2D3F Average [ F] Average [ F] Standard Dev. [ F] 8.06 Standard Dev. [ F] 2.46 Coeff. Of Var. [%] 3.47 Coeff. Of Var. [%]

100 MWDA1D7A MWDA1D8A 100

101 MWDA1D9A MWDB2D7A 101

102 MWDB2D8A MWDB2DAA 102

103 MWDC3D7A MWDC3D8A 103

104 MWDC3D9A MWDE2D7A 104

105 MWDE2D8A MWDE2D9A 105

106 MWDA1D1F MWDA1D2F 106

107 MWDA1D3F MWDB2D1F 107

108 MWDB2D2F MWDB2D3F 108

109 MWDC3D1F MWDC3D2F 109

110 MWDC3D3F MWDE2D1F 110

111 MWDE2D2F MWDE2D3F 111

112 4.0 TESTING AND REPORTING COMMENTS 112

113 Conformity data is documented and archived as part of the Lancair certification program. FAA project No. TC 1616SE-A. 113

114 APPENDIX A. DATES OF PANEL MANUFACTURE AND COPY OF FAA FORM

115 115

116 116

117 117

118 118

119 119

120 120

121 121

122 122

123 123