PAFI-MTP-002.pdf

1 | P a g e PAFI-MTP-002

Rev: A Date: May 15, 2024

PAFI Materials Compatibility

Test Plan

PAFI-MTP-002

For Public Release

PAFI-MTP-002 Rev A

PAFI-MTP-002, FAA PAFI Materials Compatibility Test Plan

Rev 0, Dated May 15, 2024

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Revision Log:

Rev

No.

Rev

Date

Affected

Page(s) Descript ion of Revision

0 05/15/2024

Al l In i t ia l Release

A 01/22/2025 19 Updated Note for missing mater ia ls to add Tygon® F-4040-A tubing.

A 01/22/2025 19 Updated Note for missing mater ia ls to c lar i fy the test data is hardness, densi ty , and volume change and the exposure temperatures are room temp and 71 °.

A 01/22/2025 76 Add cutt ing an “X” in to the paint specimen, new 3

A 01/22/2025 77 Updated i tem renumbered 4 to new 10 – 20° dr ip angle

A 1/22/2025 77 Updated paint dr ip test f igure 6 wi th new dr ip angle

A 1/22/2025 76, 77 Updated from 2L ( .5 gal lon) volume to 20L (5 gal lon) and updated the test durat ion.

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PREFACE

PAFI-MTP-002 IS FURNISHED FOR THE PURPOSE OF PUBLIC USE.

A HIGH AROMATIC ASTM D-910 FUEL FORMULATION IS REQUIRED FOR THE SCREENING TESTS.

THIS TEST PLAN REFLECTS AVIATION INDUSTRY BEST PRACTICE FOR MATERIALS TEST PLANS WITH FORMAT AND

CONTENT STRUCTURED ACCORDINGLY. PROCESSES & PROCEDURES REFLECT INDUSTRY PRACTICES FOR

GENERATING QUALIFICATION DATA.

THIS TEST PLAN SPECIFIES THE REQUIREMENTS FOR CONDUCTING COMPARATIVE MATERIALS COMPATIBILITY

SCREENING TESTS FOR A PROPOSED ALTERNATIVE FORMULATION FOR A FUEL SUFFICIENT TO BE AN ALTERNATIVE

TO ASTM D-910.

SUCCESSFUL COMPLETION OF THIS TEST PLAN PROVIDES DATA SUPPORTING FAA FLEET AUTHORIZATION(S).

THE MATERIAL IN THIS DOCUMENT PROVIDES A REFERENCE FOR USE IN THE PREPARATION OF TEST PLANS FOR THE

DEVELOPMENT OF ALTERNATIVE AVIATION FUELS. THIS DOCUMENT IS DERIVED FROM EXTENSIVE FAA AND

INDUSTRY EXPERIENCE AND BEST PRACTICES FOR EVALUATING THE SUITABILITY OF AVIATION FUELS FOR USE IN THE

PISTON POWERED GENERAL AVIATION FLEET. THIS DOCUMENT IS USED BY THE FAA TO COMPARE AND EVALUATE

NEW AVIATION FUELS RELATIVE TO THE PERFORMANCE OF 100LL AVIATION GASOLINE THAT MEETS ASTM D910.

THIS DOCUMENT IS NOT INTENDED TO PROVIDE A METHOD TO OBTAIN DATA TO SERVE AS A SHOWING OF

COMPLIANCE TO REGULATORY REQUIREMENTS FOR THE CERTIFICATION OF AIRCRAFT OR AIRCRAFT ENGINES.

THE MATERIAL IN THIS DOCUMENT DOES NOT CHANGE OR PERMIT DEVIATIONS FROM EXISTING REGULATORY

REQUIREMENTS. THIS MATERIAL IS NEITHER MANDATORY NOR REGULATORY IN NATURE. USE OF THIS DOCUMENT

OR ANY DERIVATIVE, IN AN ATTEMPT TO OBTAIN AN FAA AUTHORIZATION OF AN ALTERNATIVE AVIATION FUEL, SHOULD BE PRE-COORDINATED AND APPROVED BY THE APPROPRIATE FAA OFFICE(S) AS PART OF AN APPROVED

QUALIFICATION PROGRAM.

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TABLE OF CONTENTS

1. SC OPE

1.1. Provisos

2. OB J E CT I VE S

3. PAFI MAT ERIA LS TEST PL AN

4. APPL ICABLE MIL, FAA, SAE & ASTM REQU IREME NT S

4.1. MILITARY Handbooks & Standards

4.2. FAA Advisory Circulars & Orders

4.3. Federal Test Methods

4.4. SAE Standards

4.5. ASTM Guidance & Practices

5. DES C RIPT I ON OF TES T ARTI CLES

5.1. MIL-DTL-6000 Hose – Aircraft Hose

5.2. MIL-DTL-5593 Hose – Aircraft Hose

5.3. Fuel Bladders AKA Fuel Cells

5.4. Polysulfide Sealants and Buna-N Topcoat Testing

5.5. Additional Materials; Nitrile, Fluorosilicone, and Fluorocarbon O-rings

5.6. Paint Test

5.7. Fabric Test

5.8. Distribution Hoses

5.9. Composite Resins, Adhesives, and Fabric

5.10. Distribution Filters and Water Separators

5.11. Vendor Supplied Materials

5.12. Wing Fuel Tanks

6. DEF I NI T IONS & TERMINOLOG Y

6.1. Exposure

6.2. Calibration

6.3. Composite

6.4. Sample

6.5. Sample Set

6.6. Specimen

6.7. Validation

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7. CONFORMITY

7.1. Test Fuels

7.2. Samples

7.3. Specimens

8. SA F E TY PROCEDU RES

8.1. Sample Fill (Reference ASTM D4057, Section 5.2)

8.2. Static Charge (REFERENCE ASTM D4057)

8.2.1. GROU NDI NG (D4057-12, SECTI ON 5.4.1)

8.2.2. PERSONA L ATT I RE (D4057, SECT I ON 4.5.2)

8.3. Vapor Hazards

8.4. Personal Protective Equipment

8.5. Hydrostatic Testing Equipment

9. PRE-TES T REQ UIRE ME NT S

9.1. Specimen Identification

9.2. Pre-Exposure Baseline Data

9.3. Pre-Exposure Photographs

9.4. Laboratory Notebook

10. TE S T FACI L I TY & E QU IP ME NT

10.1. Temperature Controlled Areas

10.1.1. ELE V AT ED TEM PE RATURE CONTROLLED AREAS – OV EN S

10.2. Access Controlled Area

10.2.1. AC CE S S CONTROL

10.2.2. CONTR OLLED ACCE SS SPACE

10.3. Tensiometer with Extensometers

10.4. Calibrated / Validated Laboratory Measuring Equipment

10.5. Sample Jars

10.6. Hose Stand Rig

10.7. ASTM D381 Air Jet Evaporator

10.8. Muffle Furnace

10.9. Bladder (Fuel Cell) Exposure Rigs

10.9.1. SI MU LA TED STAND RIG

10.10. Flow Sheet Manufacture

10.11. ASTM D395 Compression Blocks

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10.12. Industry Standard Fabric Test Frames

10.13. Hydrostatic Testing Equipment

10.14. Composite Manufacturing Equipment

10.15. Glass Transition Measurement Equipment

10.16. Facility for Distribution Filter Systems

11. TE S T WI T NESS I NG

11.1. FAA

12. TE S T PRO CEDURE – TASK 1, MIL-DTL-6000 AND MIL-DTL-5593 HO S E

12.1. Hose Property Testing

12.1.1. MATERIA LS

12.1.2. SPECIMEN PREP ARA TI ON

12.1.3. EX P OS U R E

12.1.4. PO ST EXPOSURE MEA SURE ME NT S

12.1.5. CALCULA TION S

12.2. Hose Internal Soak Testing

12.2.1. MATERIA LS

12.2.2. SPECIMEN PREP ARA TI ON

12.2.3. EX P OS U R E

12.2.4. PO ST EXPOSURE MEA SURE ME NT S

12.2.5. CALCULA TION S

13. TE S T PRO CEDURE – TASK 2 BL AD D ER TES T ING PE R TSO-C80

13.1. General Materials

13.2. Simulated Stand Test

13.2.1. TE ST SPECIF IC MATER IA LS

13.2.2. SPECIMEN PREP ARA TI ON

13.2.3. EX P OS U R E

13.2.4. PO ST TES T MEASUREMENTS

13.2.5. CALCULA TION S

13.3. Volume Swell

13.3.1. TE ST SPECIF IC MATER IA LS

13.3.2. SPECIMEN PREP ARA TI ON

13.3.3. EX P OS U R E

13.3.4. PO ST TES T MEASUREMENTS

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13.3.5. CALCULA TION S

14. TE S T PRO CEDURE – TASK 3 POLYSU LFID E TA NK SE A LAN TS A ND BUNA-N TOPCOA T TE ST ING . . 54

14.1. Materials

14.2. Physical Properties Changes

14.2.1. SPECIMEN PREP ARA TI ON

14.2.2. EX P OS U R E

14.2.3. PO ST TES T MEASUREMENTS

14.2.4. VOLUM E CHA NG E

14.2.5. TE NSIL E/ELO NG A TI ON

14.2.6. HA RD N ESS

14.2.7. CALCULA TION S

14.2.8. VOLUM E CHA NG E

14.2.9. TE NSIL E/ELO NGA TI ON CH A NG E

14.2.10. HA RD N ESS CH A NG E

14.3. Peel Strength Testing (Sealants 1-7, 9)

14.3.1. SPECIMEN PREP ARA TI ON

14.3.2. EX P OS U R E

14.3.3. CLASS A AND B S EA LA NTS (SEA LA NTS 1-7A ND 9, AP PE ND IX D)

14.3.4. PO ST TES T MEASUREMENTS

14.3.5. CALCULA TION S

14.4. Buna-N Topcoat Peel Strength (Sealant 10)

14.4.1. SPECIMEN PREP ARA TI ON

14.4.2. EX P OS U R E

14.4.3. PO ST TES T MEASUREMENTS

14.4.4. CALCULA TION S

14.5. Buna-N Topcoat Non-volatile Content

14.5.1. SPECIMEN PREP ARA TI ON

14.5.2. EX P OS U R E

14.5.3. PO ST TES T MEASUREMENTS

14.5.4. CALCULATIONS

15. TE S T PRO CEDURE – TASK 4 AD D I T I ONA L ELAST OME R TES T ING

15.1. Compression Set

15.1.1. MATERIA LS

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15.1.2. SPECIMEN PREP ARA TI ON

15.1.3. EX P OS U R E TE ST I NG

15.1.4. PO ST TES T MEASUREMENTS

15.1.5. CALCULA TION S

15.2. Tensile/Elongation and Hardness

15.2.1. MATERIA LS

15.2.2. SPECIMEN PREP ARA TI ON

15.2.3. EX P OS U R E TE ST I NG

15.2.4. PO ST EXPOSURE MEA SURE ME NT S

15.2.5. CALCULA TION S

16. TE S T PRO CEDURE – TASK 5 PAI NT STA I NI NG A ND ADH ES I ON TEST I NG

16.1. Staining and Adhesion Tests

16.1.1. MATERIA LS

16.1.2. SPECIMEN PREP ARA TI ON

16.2. Adhesion Exposure Testing

16.2.1. PO ST EXPOSURE MEA SURE ME NT S

16.2.2. CALCULA TION S

16.3. Paint Staining Exposure Testing

16.3.1. PO ST EXPOSURE MEA SURE ME NT S

16.3.2. CALCULA TION S

17. TE S T PRO CEDURE – TASK 6 FABRI C TE STI NG

17.1. Fabric Sample Construction

17.1.1. MATERIA LS

17.1.2. SPECIMEN PREP ARA TI ON

17.2. Test Execution

17.2.1. MATERIA LS

17.2.2. SPECIMEN PREP ARA TI ON

17.2.3. EX P OS U R E

17.2.4. PO ST EXPOSURE MEA SURE ME NT S

17.2.5. CALCULA TION S

18. TE S T PRO CEDURE – TASK 7 DIS T RIBUTI ON HOSE TES TI NG

18.1. Physical Properties and Adhesion

18.1.1. MATERIA LS

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18.1.2. SPECIMEN PREP ARA TI ON

18.1.3. PH YSI CA L PRO PERT I ES (DE NS IT Y, VOLUME, A ND HARD NESS)

18.1.4. IN NER L IN ER ADH ES I ON TES TIN G

18.1.5. EX P OS U R E

18.1.6. PO ST EXPOSURE MEA SURE ME NT S

18.1.7. CALCULA TION S

18.2. 16 Week Static Exposure and Proof Pressure Testing

18.2.1. MATERIA LS

18.2.2. SPECIMEN PREP ARA TI ON

18.2.3. EX P OS U R E

18.2.4. PO ST EXPOSURE MEA SURE ME NT S

18.2.5. VIS UAL INS PE CT IONS

18.2.6. PERFORM HYDROSTA TI C P ROOF PRESS URE TES TI NG

19. TE S T PRO CEDURE – TASK 8 COMPO SI TE TE S TI NG

19.1. Composite Resin Screening Test

19.1.1. MATERIA LS

19.1.2. SPECIMEN PREP ARA TI ON

19.1.3. EX P OS U R E

19.1.4. PO ST EXPOSURE MEA SURE ME NT S

19.2. Properties Testing – Finished Composites

19.2.1. MATERIA LS

19.2.2. SPECIMEN PREP ARA TI ON

19.2.3. TE ST PA NE LS LA Y-UP

19.2.4. LAM INA TING RESI N COUPON CONSTRUCTION

19.2.5. PREPREG COUPO N CONSTRUC TION

19.2.6. ADH E SI VE JOINT CO UPON CONSTRUCTIO N

19.2.7. SURFACE PREPARATION

19.2.8. ADH E SI VE P R EPA R A TI O N

19.2.9. APPLY ADHESIVE

19.2.10. CU TT I NG LAM INA T ES I NTO SP EC I M E NS

19.2.11. LABEL I NG SPEC IM ENS

19.2.12. ADD I NG BOND ED TA BS TO SP EC IM ENS

19.2.13. TRAVELER COU PONS

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19.2.14. RECTANG ULAR TENS ILE COUPONS

19.2.15. SH ORT BEAM CA NTIL EVER SPECIMENS

19.2.16. V-NOTCH SHE A R SPE CI ME NS

19.2.17. ADH E SI VE JOINT SA MP L ES

19.2.18. PRE-EX P OS URE MEASUREMENTS

19.2.19. DI ME NS I O NS

19.2.20. DE NS I TY

19.2.21. HA RD N ESS

19.2.22. PH OT OG RA PH IC/VI SU A L DOC UMENTATION

19.2.23. TE NSIL E, STRA IN, AN D MODULUS

19.2.24. CALCULA TING TE ST RES UL TS

19.2.25. SH ORT BEAM CA NTIL EVE R

19.2.26. CALCULA TING TE ST RES UL TS

19.2.27. V-NOTCH SHE A R STRE NG TH

19.2.28. CALCULA TING TE ST RES UL TS

19.2.29. ADH E SI ON STRENG TH (LA P SH E AR)

19.3. Exposure

19.4. Post Test Exposure

20. DIS T RIBU TI ON F I LT ER, COA LE SCE R,& TA NK COA T IN G S

20.1. General Materials

20.2. Pleated Filter Test

20.2.1. TE ST SPECIF IC MATER IA LS

20.2.2. SPECIMEN PREP ARA TI ON

20.2.3. EX P OS U R E

20.2.4. PO ST TES T MEASUREMENTS

20.2.5. CALCULA TION S

20.3. Water Coalescer Test

20.3.1. TE ST SPECIF IC MATER IA LS

20.3.2. SPECIMEN PREP ARA TI ON

20.3.3. EX P OS U R E

20.3.4. PO ST TES T MEASUREMENTS

20.3.5. CALCULA TION S

20.4. Water Reaction Testing

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20.5. Interfacial Tension (Surface Tension)

20.5.1. CALCULA TION S

20.6. Material migration by Vacuum Filtration

20.6.1. CALCULA TION S

20.7. Distribution Tank Coatings

20.7.1. TE ST SPECIF IC MATER IA LS

20.7.2. SPECIMEN PREP ARA TI ON

20.7.3. EX P OS U R E

20.7.4. PO ST TES T MEASUREMENTS

20.7.5. CALCULA TION S

21. VENDOR SU PPLI ED MATERIA LS

21.1. General Materials

21.2. Flat Stock

21.3. Tensile/Elongation, Hardness, Density, and Volume

21.3.1. MATERIA LS

21.3.2. SPECIMEN PREP ARA TI ON

21.3.3. EX P OS U R E TE ST I NG

21.3.4. PO ST EXPOSURE MEA SURE ME NT S

21.3.5. CALCULA TION S

21.4. Shaped Specimens

21.4.1. MATERIA LS

21.4.2. SPECIMEN PREP ARA TI ON

21.4.3. EX P OS U R E TE ST I NG

21.4.4. PO ST EXPOSURE MEA SURE ME NT S

22. MA NU FA C TURE R CONT ROLLE D WIN G TES T

22.1. Test Specific Materials

22.2. Specimen Preparation

22.3. Exposure

22.4. Post Test Measurements

23. PAS S/FA I L CRI TERI A

23.1. Task 1 – MIL-DTL-6000 Hose Test

23.1.1. HO S E PROP ERTY TE S TI NG

23.1.2. HO S E INT E RNAL SOAK TE S TI NG

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23.2. Task 2 –Bladder

23.3. Task 3 – Polysulfide Testing

23.4. Task 4 –Elastomeric Testing (O-rings)

23.5. Task 5 – Paint Testing

23.6. Task 6 – Fabric Testing

23.7. Task 7 – Distribution Hose Testing

23.8. Task 8 – Composite Resin and Fabric

23.8.1. IN IT IA L SC REE NI NG TES T OF NEA T RES IN AND AD H E SIVE S

23.8.2. PH YSI CA L PRO PERT Y TES TI NG OF F INISHED COMPOSI T ES

23.9. Task 9 – Distribution Fuel Filters/Coalescers

23.9.1. HOU SING S

23.9.2. FI LT ER CARTRI DG ES

23.9.3. COALESC ER CARTRIDGES

23.10. Task 10 – Vendor Supplied Materials

23.11. Task 11 – Wing Tank Testing

24. TE S T PE R S ONN EL

25. TE S T RES ULTS REP ORT

26. RE F E R EN CE S

27. APPE ND IC ES

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TABLE OF APPENDICES

APPENDIX A – TEST FUEL COA REQUIREMENTS

APPENDIX B – FLOW PATH OF TESTING REQUIREMENTS

APPENDIX C – PRODUCTION OF AS5127/1C FLOW SHEETS

APPENDIX D – INTEGRAL FUEL TANK SEALANTS

APPENDIX E – ADDITIONAL MATERIALS AS O-RINGS

APPENDIX F – PAINT SYSTEMS

APPENDIX G – FABRIC SYSTEMS

APPENDIX H - LARGE DISTRIBUTION HOSES

APPENDIX I – COMPOSITES MATERIALS

APPENDIX J – DISTRIBUTION FILTERS/COALESCERS AND TANK COATINGS

APPENDIX K – VENDOR SUPPLIED MATERIALS

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Materials Compatibility Test Plan

1. SCOPE

This test plan specif ies the requirements and procedures for conducting comparative compatibi l i ty test ing of materials, required for part ic ipat ing in the FAA Piston Aviat ion Fuels Ini t iat ive (PAFI) test program.

This data wi l l be used for the evaluat ion of an unleaded fuel being tested in the PAFI test program. The data wi l l be used as part of the f inal evaluat ion of data for f leet authorizat ion(s). Use of this test plan generates data meeting the appl icable requirements of [FAA 14 CFR Parts 23 and 33] or ASTM D7826 for material compatibi l i ty.

Speci f ic objectives of this plan are stated as fol lows. Specif ied mater ials l is ts are located in Appendices at the end of this document.

1) Execute compatibi l i ty screening of MIL-DTL-6000 Hose, Rubber, Aircraft, Fuel, Oi l, Coolant, Water, And Alcohol, and MIL-DTL-5593 Hose, Aircraft, Low Pressure Air and Vacuum, Flexible, related to determining swell character ist ics, and changes tensi le/elongation propert ies fol lowing fuel exposure.

2) Execute compatibi l i ty screening of specif ied fuel bladder construction related to degradation and delamination of the internal l ining fol lowing fuel exposure in compliance with appl icable parts of FAA TSO-C80 and ASTM D7826.

3) Execute compatibi l i ty screening of specif ied integral fuel tank sealants related to changes to tensi le/elongation, volume swel l and peel strength propert ies fol lowing fuel exposure. Specif ied materials are provided in Appendix D.

a. The l ist of integral fuel tank sealants includes a low strength access panel sealant and a l iquid Buna-N topcoat which have material specif ic variat ions to the described required testing. Dif ferences are provided.

4) Execute compatibi l i ty screening of specif ied nitr i le, f luorosi l icone, and f luorocarbon elastomers in the form of O-r ings, related to changes in hardness, tensi le/elongation, volume change and compression set fol lowing fuel exposure. These materials are in addit ion to the ful l materials l ist specif ied in ASTM D7826. Specif ied materials are provided in Appendix E.

5) Execute comparison testing of paint staining and adhesion impacts of a specif ied matr ix of paint systems fol lowing fuel exposure. Specif ied materials are provided in Appendix F.

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6) Execute comparison test ing of fabric tensi le/elongation of specif ied fabric systems fol lowing fuel exposure. Specif ied materials are provided in Appendix G.

7) Execute comparison testing of physical propert ies and long-term f i l l impacts of specif ied manufacturers of large distr ibution hoses. Specif ied materials are provided in Appendix H.

8) Execute comparison testing of specif ied resins, adhesives, foam cores, and fabrics used for composite structure construction. Specif ied materials are provided in Appendix I.

9) Execute comparison test ing of f i l ter elements, coalescer elements, and housings, and fuel tank coatings used in distr ibut ion systems. Specif ied materials are provided in Appendix J.

10) Execute comparison test ing of vendor suppl ied materials used by or iginal equipment manufacturers. Specif ied materials are provided in Appendix K.

The fol lowing test plan includes the requirements for conf irming basel ine propert ies, test set-up, instrumentat ion, and support ing documentation such as material and fuel cert i f ication documents as prerequisi tes to the test ing identi f ied.

This test plan is used in conjunct ion with ASTM D7826 to prepare data packages for review of a fuel for f leet authorization(s).

Comparat ive testing of materials for screening purposes is executed at speci f ied temperatures and durations which may be modif ications from exist ing industry standards. The modif ications have been selected by industry representat ives as providing the desired screening data suff ic ient for consideration of a proposed unleaded fuel for acceptance into the FAA PAFI fuel testing program.

This PAFI Materials Test Plan, consists of tasks executed in addit ion to ASTM D7826 materials compatibi l i ty test ing to document physical changes in materials as compared to those changes experienced by a D910 compliant 100LL aviation gasoline produced with a high aromatic content. Although Specif icat ion D910 does not include an expl ici t maximum aromatic l imit , other specif ication l imits effect ively restr ict the aromatic content of aviat ion gasolines. For this testing, the high aromatic ASTM D910 compliant test fuel shall be fuel produced with 15% (- 0%/+3%) toluene by volume per ASTM D3606. All other Table 1 propert ies shal l be D910 compliant. In addit ion, the unleaded fuel shal l be a “worst case” fuel for material compatibi l i ty test ing. Worst case is defined as a fuel blended with the maximum amounts of reactive components permitted by the offered fuel ’s standard. React ive components include, but not are not l imited to, aromatics, alcohols, ethers, amines, and other chemicals not tradit ional ly used in aviation gasoline. Maximum amounts are defined by the maximum amounts permitted in the fuel by the respective fuel standard, be that an industry standard, company standard, or other control l ing document . While this blend should be compliant to the target standard, i t is recognized that the blending of the fuel to have this maximum content may not produce an “optimum fuel” for performance and operation. Data from both the unleaded test fuel and the high aromatic content

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100LL aviat ion gasol ine exposure wi l l be further compared to the exist ing pass/fai l cri ter ia developed for material cert i f ication. In cases where the 100LL does not meet the pass/fai l cr i ter ia provided, the result ing 100LL data wi l l be used as a measure of minimum performance.

Requirements for confirming test equipment configuration, test instrumentat ion, and support ing documentat ion such as fuel cert i f ication are pre-requisi tes to the test ing ident if ied.

I t is known under certain condit ions, exposure to l ight can cause precipi tat ion of the tetraethyl lead and fading of the dye in 100LL fuels. In order to avoid confounding of the test data, al l fuel shall be stored in a manner which wil l minimize exposure to l ight, part icularly sunl ight. This includes bulk samples, such as 5-gal lon specimens, laboratory specimens, and specimens during testing.

Where possible, the fuel shal l be stored in metal cans, brown borosi l icate laboratory bott les, or containers wrapped in foi l . Alternat ively, fuel may be stored in clear laboratory glassware with the expectation i t wil l be stored in low/no l ight locations such as a f lammables cabinet or during oven testing.

1.1. PROVISOS

The fol lowing ident i f ies signif icant assumptions, requirements, and provisions associated with the testing prescribed within this test plan. Test ing performed pursuant to this test plan provides data support ing FAA f leet authorizat ion(s) for PAFI unleaded fuels. Test ing performed to this test plan must be witnessed by an identi f ied designated representat ive of the FAA. This may be achieved through the use of a Designated Engineering Representat ive (DER), or other representat ive approved by the AIR-650 or PAFI Advisory Committee prior to executing test ing.

Al l the resul ts of the test ing performed, and the associated data col lected under the fol lowing test plan are considered competit ion sensit ive and proprietary by the fuel offeror and are subject to NDA between the FAA and the Fuel Offeror.

2. OBJECTIVES

The object ives of this document are in addit ion to the materials compatibi l i ty test ing of ASTM D7826. The specif ied materials for test ing covered by this document are referenced in separate appendices at the end of this document. The object ives of the PAFI Materials Test Plan comparat ive materials compatibi l i ty tests are defined as fol lows .

1) Demonstrate changes in tensi le/elongation and changes in volume swel l within specif ied l imits or no greater than that experienced with 100LL when MIL-DTL-6000 ni tr i le hose is exposed to fuel at 21-27 °C )70 – 80 °F) for 48 and 24 hours respect ively.

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2) Demonstrate swell ing within specif ied l imits or no greater than that experienced with 100LL when MIL-DTL-6000 ni tr i le hose and MIL-DTL- 5593 are exposed serial ly to fuel at room temperature and fresh fuel at 71 °C (160 °F) for 30 days at each temperature.

3) Demonstrate no cracking, bl ister ing, delaminat ion or other visual surface degradation of the internal surface of fuel bladder sheets fol lowing exposure to the fuel at 60 °C (140 °F) for 42 days (~1000 hours).

4) Demonstrate non-volat i le gum residues from fuel exposed to a standard fuel bladder panel within specif ied l imits when tested in compliance with the modif ied TSO-C80 simulated stand test.

5) Demonstrate swell ing, changes in tensi le/elongation, and changes in hardness of specif ied internal tank sealants prepared in compliance to SAE AS5127, Section 7.7 is within specif ied l imits or no greater than 100LL when exposed to fuel at 60 +3/ -0 °C (140 +5/ -0 °F) for 42 days (~1000 hours). Testing wi l l include fresh fuel exchange at day 14 and 28.

The tensile/elongation and hardness changes shal l be stabi l ized to within 10% of the day 14 value to assure an endpoint in fuel property changes.

See Appendix D for materials.

6) Demonstrate changes in peel strength of specif ied internal tank sealants prepared in compliance with ASE AS5127, Sect ion 8.0 are within specif ied l imits or no greater than that experienced with 100LL when exposed to fuel at 60 +2/-0 °C (140 +5/-0 °F) after 42 days with fresh fuel changes at day 14, and 28. See Appendix D for materials.

7) Demonstrate changes in peel strength of specif ied internal tank sealants prepared in compliance with ASE AS5127, Sect ion 8.0 are within speci f ied l imits or no greater than that experienced with 100LL when exposed to 100LL at 60 +2/-0 °C (140 +5/-0 °F) for 70 days fol lowed by exposure to ei ther 100LL (baseline) or test fuel for 70 days at 60 +2/-0 °C (140 +5/-0 °F)

8) Demonstrate changes in peel strength of PR-1005-L Buna-N slosh coat ing prepared in compliance with AMS-S-4383, 4.6.8 are within specif ied l imits or no greater than that experience with 100LL when exposed for 48 hours at 25 ° ± 1 °C (77 ° ± 2) fol lowing 72 hours of air cure and 24 hours at 49 °C (120 °F).

9) Demonstrate changes in extracted gum residues from Buna-N topcoat sealant is less than 20 mg/ 100 mL or no greater than that experienced with 100LL when exposed to fuel at room temperature for 48 hours.

10) Demonstrate swel l ing, and changes to tensi le/elongation, hardness, and compression set within specif ied l imits or no greater than that experienced with 100LL when specif ied nitr i le, f luorosi l icone and

18 | P a g e f luorocarbon (Viton™) O-r ings are exposed to fuel at 71 ±3 °C (160 ±5 °F) for 42 days. Testing wi l l include fresh fuel exchange at day 14 and 28. The tensi le/elongation and hardness changes shal l be stabi l ized to within 10% of the day 14 value to assure an endpoint in fuel property changes. See Appendix E for materials.

11) Demonstrate that a matr ix of paint systems does not experience staining, change in hardness, or loss of adhesion greater than that experienced with 100LL when exposed to fuel at room temperature for 28 days with a fuel change and visual inspection at day 14. See Appendix F for materials.

12) Demonstrate that a matr ix of paint systems does not experience staining or removal when exposed to fuel at room temperature as a dr ip to the surface under control led condit ions of rate and volume. See Appendix F for mater ials.

13) Demonstrate that a matr ix of specif ied fabric systems does not experience a loss of tensile/elongation, adhesion, or cross-l inking (bl istering, bubbling, removal, etc.) greater than that experienced with 100LL when exposed to fuel at room temperature for 48 hours. Visual inspection and maintenance of a fuel reservoir wi l l be done after 30 minutes, 1 hour, 4 hours, 8 hours, 24 hours, and 48 hours. Frequency of maintaining the fuel reservoir wi l l be dictated by the volati l i ty of the test fuel. See Appendix G for materials.

14) Demonstrate that changes in hardness, volume, and density of specif ied large distr ibution hoses is no greater than that experienced with 100LL when exposed to fuel at 71 °C (160 °F) for 28 days. See Appendix H for materials.

15) Demonstrate that changes in permeation, performance, and hydrostat ic proof pressure of specif ied large distr ibut ion hoses are no greater than that experienced with 100LL when exposed to fuel at ambient condit ions for 16 weeks. See Appendix H for materials.

16) Demonstrate that changes in weight gain, tensile/elongation, and break strength of specif ied composite matr ices are no greater than those experienced with 100LL when exposed to fuel at ambient condit ions for 28 days. See Appendix I for materials.

17) Demonstrate that changes in housing condit ion are no greater than those experienced with 100LL when exposed to fuel at ambient condit ions for 500 hours. See Appendix J for materials.

18) Demonstrate that changes in f i l ter cartr idge dimensions and condit ion are no greater than those experienced with 100LL when exposed to fuel at ambient condit ions for 500 hours. See Appendix J for materials.

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19) Demonstrate that changes in f i l ter coalescer condit ion are no greater than those experienced with 100LL when exposed to fuel at ambient condit ions for 500 hours. See Appendix J for materials.

20) Demonstrate that changes in fuel water react ion, surface tension, and material migration are no greater than those experienced with 100LL when exposed to fuel at ambient condit ions for 500 hours. See Appendix J for materials.

21) Demonstrate that changes in vendor suppl ied materials are no greater than those observed in 100LL baseline fuel . See Appendix K for materials.

22) Individual airframe manufacturers may select aircraft for further test ing of fuel tank performance. This includes but is not l imited to identify ing aircraft with “wet wings” and performing testing as determined by the manufacturer. This testing wi l l be for evaluat ing compatibi l i ty and funct ional i ty of the sealants fol lowing exposure to test fuels. Test ing wi l l be done at the manufacturers, or at their designated location with aircraft owned by or designated by the manufacturer.

3. PAFI MATERIALS TEST PLAN

This test plan provides materials and test procedures which are in addit ion to those presented in ASTM D7826. ASTM D7826 is a guidance document which includes material compatibi l i ty testing on metal l ic and non-metal l ic materials and the testing to be performed. All of the mater ials compatibi l i ty test ing in ASTM D7826 are to be completed. The fol lowing test plan includes materials or procedures which are not currently included in ASTM D7826, or which are deviat ions from ASTM D7826. In cases where materials or tests are in both ASTM D7826 and this document, this document shal l take precedence.

NOTE: ASTM D7826 INCLUDES HYSOL EA9628 STRUCTURAL METAL

BONDING ADHESIVE IN THE MATERIALS LIST . I t does not, however, clearly indicate that the use of Solvay BR-127 epoxy pr imer is required for test panel construction. Furthermore, due to the di f f icul ty in procuring the EA9628 adhesive, i t is recommended the offeror work with the FAA and Piper to procure f inished panels for the testing. This update is intended to be added to ASTM D7826 in a future revision, but at this t ime is not explained in D7826.

NOTE: ASTM D7826 does not currently include acetal resin (Delrin) or Tygon® F-4040-A tubing in the materials l ist. Testing of Delrin and Tygon® F- 4040-A shal l be added to the materials l ist of ASTMD7826. Al l non-metal l ic test protocols found in D7826 shall be performed on acetal resin and Tygon® tubing, and tested for changes in hardness, density, and volume. Materials shall be tested at room temperature and 71°C. These materials are intended to be added to ASTM D7826 in a future revision.

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The individual tasks encompassed in the PAFI Materials Test Plan are presented in the fol lowing sections of this document. Each test fol lows a common format with general procedures, processes, and test instrumentat ion common to each test.

See referenced Appendices for specif ic materials l ists.

1) MIL-DTL-6000/MIL-DTL-5593 Hose Test

2) Bladder (Fuel Cel l) s imulated stand test on sheets

3) Integral tank sealant (Polysulf ide) Screening Tests

4) Addit ional Elastomeric Material (O-ring) Testing

5) Paint Staining and Adhesion Test ing

6) Fabric Strength and Cross-Linking Testing

7) Large Distr ibution Fuel Hose Physical Propert ies and Performance Testing

8) Composite Resin and Fabric Screening Testing

9) Distr ibut ion System Fil t rat ion/ Coalescence Element Compatibi l i ty and Fuel

Tank Coating Test ing

10) Vendor Suppl ied Materials

The test plans may be executed by a third-party organizat ion contracted by the fuel formulator in order to generate and collect the specif ied data. Integral fuel tank sealants test protocols are designed to be executed with part icipat ion of the product OEM’s or other AS 9100 approved test faci l i t ies. Al l test ing must be witnessed by a designated representat ive of the FAA. This data is considered acceptable for inclusion into the f inal FAA assessment for f leet authorization.

To be considered for f leet authorizat ion, the test plans prepared to support the FAA PAFI Materials Test Plan for unleaded fuels are subjected to the fol lowing review and approval protocol .

1) The FAA test plans fol low a format and content consistent with establ ished practices.

2) Draft test plans are furnished to the FAA AIR600 off ice for review and approval. These test plans shall include, at a minimum, the location of test ing, the specif ic materials and equipment to be used, and the plans for test witnessing by an FAA designated representat ive.

3) Upon concurrence from AIR600 Alternat ive Fuel Program Staff (AFPS),

4) A f inal test plan wil l be released incorporating changes resul t ing from AIR600 review.

5) Al l changes and referrals to this test plan should reference the latest revision level and date.

4. APPLICABLE MIL, FAA, SAE & ASTM REQUIREMENTS

The fol lowing is a l ist ing of the applicable FAA, SAE, and ASTM documents which contain information relevant to the testing specif ied by this test plan. The

21 | P a g e latest revision number should be used unless otherwise indicated. The revision number used for testing shal l be recorded.

4.1. MILITARY HANDBOOKS & STANDARDS

Mil i tary reference material and standards applicable to the testing identi f ied are l isted as fol lows.

1) MIL-HDBK-510-1D “Department of Defense Handbook, Aerospace Fuels Cert i f ication”

2) MIL-DTL-5593 “Hose, Aircraft, Low Pressure Air and Vacuum, Flexible”

3) MIL-DTL-6000 “Hose, Rubber, Aircraft , Fuel, Oi l , Coolant, Water, And Alcohol”

4) MIL-PRF-6855 “Rubber, Synthet ic, Sheets, Strips, Molded or Extruded Shapes, General Specif ication For”

5) MIL-DTL-25988 “Rubber, Fluorosi l icone Elastomer, Oil– And Fuel– Resistant, Sheets, Str ips, Molded Parts, And Extruded Shapes” (Supersedes SAE-AMS-R-25988)

6) CCC-C-432 “Cloth, Sheeting, Cotton, (Unbleached, Bleached, and Dyed) (Supersedes Fed. Spec. CCC-C-432) Inactivated 11 Apri l 2002

4.2. FAA ADVISORY CIRCULARS & ORDERS

1) FAA Advisory Circular 33.19-1,” Guidance Material for 14 CFR §33.19 Durabil i ty for Reciprocat ing Engine Redesigned Parts”

2) FAA Advisory Circular AC33.4-1,” Instructions for Continued Airworthiness”

3) FAA Order 8110.4C, “Type Cert i f icat ion Process”

FAA guidance and reference material applicable to Part 33 reciprocating engines are l isted as fol lows.

1) FAA Advisory Circular 33.19-1,” Guidance Material for 14 CFR §33.19 Durabil i ty for Reciprocat ing Engine Redesigned Parts”

2) FAA Advisory Circular AC33.4-1,” Instructions for Continued Airworthiness”

3) FAA Order 8110.4C, “Type Cert i f icat ion Process”

4) FAA Technical Order C80, “Subject: TSO-C80, Flexible and Oil Cel l Material”

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4.3. FEDERAL TEST METHODS

1) Federal Test Method Standard No. 601, Apri l 12, 1955 “Rubber: Sampling and Testing”, Method 4111, “Tensile Strength”.

4.4. SAE STANDARDS

SAE standards appl icable to the testing ident if ied are l isted as fol lows.

1) SAE AS5127 “Aerospace Standard Test Methods for Aerospace Sealants Two-Component Synthetic Rubber Compounds”

2) SAE AMS3276 “Seal ing Compound, Integral Fuel Tanks and General Purpose, Intermit tent Use to 360 °F (182 °C)”

3) SAE AMS3277 “Seal ing Compound, Polythioether Rubber Fast Curing for Integral Fuel Tanks & General Purpose, Intermittent Use to 360°F (182°C)”

4) SAE AMS3281 “Sealing Compound, Polysulf ide (T) Synthet ic Rubber for Integral Fuel Tank and Fuel Cel l Cavit ies Low Density for Intermittent Use to 360 °F (182 °C)”

5) SAE AMS3284 “Seal ing Compound, Low Adhesion, for Removable Panels and Fuel Tank Inspection Plates”

6) SAE AMS-S-4383 “Seal ing Compound, Topcoat, Fuel Tank, Buna-N Type”

7) SAE AMS-P-5315 “Acrylonitr i le-butadiene (NBR) Rubber For Fuel-Resistant Seals 60 to 70”

8) SAE AMS-7276 “Rubber: Fluorocarbon (FKM) High-Temperature-Fluid Resistant Low Compression Set For Seals In Fuel Systems and Specif ic Engine Oil Systems”

9) SAE AMS7379 “Rubber: Fluorocarbon Elastomer (FKM) Low Temperature Seal ing Tg -40 °F (-40 °C) 70 to 80 Type ‘A’ Hardness For Elastomeric Seals in Aircraft Engine Oil , Fuel and Hydraul ics Systems”

10) SAE AMS7287 “Fluorocarbon Elastomer (FKM) High Temperature / HTS Oi l Resistant / Fuel Resistant Low Compression Set / 70 to 80 Hardness, Low Temperature Tg -22 °F (-30 °C) For Seals in Oi l / Fuel / Specif ic Hydraul ic Systems” – Replaces SAE AMS-R-83485, Type 1

11) SAE AMS-S-8802 “Seal ing Compound, Fuel Resistant, Integral Fuel Tanks and Fuel Cell Cavit ies”

12) SAE-AMS-R-25988, “Rubber, Fluorosi l icone Elastomer, Oi l-and-Fuel- Resistant, Sheets, Str ips, Molded Parts, and Extruded Shapes” – Cancel led, Superseded by MIL-DTL-25988

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13) SAE-AMS-R-83485 “Rubber, Fluorocarbon Elastomer, Improved Performance at Low Temperatures”–Cancel led, Type 1 replaced by AMS7287

14) AMS-QQ-A-250/5B “Aluminum Al loy Alclad 2024, Plate and Sheet”

15) SAE J905 SEP2009 Fuel Fi l ter Test Methods

4.5. ASTM GUIDANCE & PRACTICES

ASTM guidance and standards applicable to the testing identi f ied are l isted as fol lows. Data provided by this test plan wi l l support development of an ASTM product ion specif icat ion for each of the unleaded fuels. Within this document, references to content may be revision speci f ic, for example section references, however use of the most current version of the standards are permissible. STM is ”Standard Test Method”

1) ASTM D380 “STMs for Rubber Hose”

2) ASTM D381 “STM for Gum Content in Fuels by Jet Evaporat ion”

3) ASTM D395 “STMs for Rubber Property—Compression Set”

4) ASTM D412 “STMs for Vulcanized Rubber and Thermoplastic Elastomers— Tension”

5) ASTM D413 “STMs for Rubber Property – Adhesion to Flexible Substrate”

6) ASTM D471 “STM for Rubber Property—Effect of Liquids”

7) ASTM D1094 “STM for Water Reaction of Test Fuels”

8) ASTM D1331 “STM for Surface and Interfacial Tension of Solut ions of Paints, Solvents, Solut ions of Surface-Act ive Agents, and Related Materials”

9) ASTM D1414 “STMs for Rubber O-Rings”

10) ASTM D2240 “STM for Rubber Property—Durometer Hardness”

11) ASTM D2276 “STM for Part iculate Contaminant in Aviat ion Fuel by Line Sampling”

12) ASTM D2344 “STM for Short-Beam Strength of Polymer Matr ix Composite Materials and Their Laminates”

13) ASTM D2583 “STM for Indentat ion Hardness of Rigid Plast ics by Means of a Barcol Impressor”

14) ASTM D3039 “STM for Tensi le Propert ies of Polymer Matr ix Composite Materials

24 | P a g e

15) ASTM D3163 “STM for Determining Strength of Adhesively Bonded Rigid Plastic Lap-Shear Joints in Shear by Tension Loading”

16) ASTM D3359 “STM for Measuring Adhesion by Tape Test”

17) ASTM D3363 “STM for Fi lm Hardness by Pencil Test”

18) ASTM D3505 “STM for Density or Relat ive Density of Pure Liquid Chemicals”

19) ASTM D5035 “STM for Breaking Force and Elongation of Texti le Fabrics (Strip Method)”

20) ASTM D5379 “STM for Shear Propert ies of Composite Materials by the V- Notched Beam Method”

21) ASTM D7826 “Standard Guide for Evaluation of New Aviation Gasol ines and New Aviation Gasoline Addit ives”

5. DESCRIPTION OF TEST ARTICLES

This test plan covers the screening materials compatibi l i ty of mult iple test art ic les.

Mult iple test art ic les may be required within each individual task. Detai ls in this section are in addit ion to or in l ieu of materials described in ASTM D7826.

5.1. MIL-DTL-6000 HOSE – AIRCRAFT HOSE

In order to complete the hose testing, two sizes of MIL-DTL-6000 compliant hoses are required.

1) 3/8” or -6 hose in 12-to-15-inch sections; a total of a minimum of 10 cont inuous feet. In order to perform the necessary fuel gum testing, four 12 to 15 inch specimens per tested fuel are required. A total of eight specimens are required per fuel set ( four for experimental fuel and four for 100LL aviation gasol ine). This hose is used to prepare the diameter swell test ing.

2) 2” ( -32) hose minimum up to 2 ½” (-40); a total of 9 feet. This size hose is used for tensile/elongation and volume change testing and wi l l be used to prepare ASTM D412, Die C tensi le str ips and 1”x2” volume change specimens. The hose must be a minimum diameter of 2” to provide suff icient length for Die C tensi le str ips. Due to manufacturing schedules, avai labi l i ty of large diameter hose may require the purchase of larger diameter MIL- DTL-6000 hose up to 2 ½”. This is permissible as long as the hose is not reinforced, i .e., wi th metal braid.

3) Hose ends and AN fi t t ings used to cap and seal the hose specimens. These f i t t ings shal l be instal led into the -6 hose using industry standard assembly processes.

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5.2. MIL-DTL-5593 HOSE – AIRCRAFT HOSE

In order to complete the hose test ing, length(s) of hose must be procured from Piper (P/N 187-058 Bulk Hose). The mil i tary specif icat ion is insuff ic ient in specifying the material and construction of the hose specif ic to use by Piper.

1) 3/8” or -6 hose in 12-to-15-inch sections; a total of a minimum of 10 cont inuous feet. In order to perform the necessary fuel gum testing, four 12 to 15” specimens per tested fuel are required. A minimum of eight specimens are required per fuel set ( four for the experimental fuel and four for the 100LL aviat ion gasol ine). This hose is used to prepare the diameter swell test ing.

2) Hose ends and AN fi t t ings used to cap and seal the hose specimens. These f i t t ings shal l be instal led into the -6 hose using industry standard assembly processes.

5.3. FUEL BLADDERS AKA FUEL CELLS

In order to complete the Simulated Stand testing, samples from mult iple manufacturers are required. The samples are prepared from ful ly constructed bladder including an airworthy patch and a seam in the form of panels. The sheets may be cut from finished, purchased fuel cells.

The ful ly constructed panel for the simulated stand test can be achieved by cutt ing the panels from fuel cel ls manufactured under ei ther FAA-PMA or an original equipment product and suppl ied with an FAA Form 8130-3. The specimens shal l be cut from the fuel bladder in a manner to include a f lat area across which there is a seam. The airworthy patch may be prepared prior to cutt ing the specimens or after the specimens have been prepared. Patching shal l be in accordance with appl icable ICA’s ( Instruct ions for Continued Airworthiness).

Specimens to be used for the simulated stand test wi l l be cut from an open area to produce a set of panels of suff ic ient size to f i t the chosen exposure test r ig (See Section 10.9). Panel shal l be f lat without corners or mounting hardware.

Fuel cel l part numbers which have been ident i f ied as acceptable include:

1) 2F1-6-32514-17

2) 2F1-6-37819-18

5.4. POLYSULFIDE SEALANTS AND BUNA-N TOPCOAT TESTING

The integral tank sealants must be prepared as cured f low sheets as described in AS5127, Section 7.7 Tensi le Strength and Elongation, see Appendix D for sealant descript ions. The sealants, except for AMS 3284 Low Adhesion Sealing Compound, and AMS-S-4383 Buna-N Topcoat must also be prepared for peel

26 | P a g e test ing as described in AS5127, Section 8. Addit ional ly, AMS 3281 sealant is also to be tested appl ied to BT250/eglass f iber reinforced composite panels.

One way tank sealants are procured is in a Semkit® package which is a complete, mult i-component plastic cartr idge assembly which stores, mixes, and applies mult iple component sealants. Suff ic ient Semkits® must be procured to produce f low sheets suff ic ient to prepare the ASTM D412 Die C tensi le str ips and the ASTM D471 dimension change specimens, and to prepare the peel strength specimens.

The number of Semkits® required is determined by the size of the f low sheets, the number of specimens required, and the number of peel strength specimens.

Sealants shall be specif ied as being produced from the same lot of sealants. I f mult iple lots of material must be used, al l specimens within a type, for example the f low sheets, shall be from the same lot. The goal is to assure that the specimens exposed to the basel ine 100LL fuel are from the same lot as those exposed to the test fuel.

This test protocol requires the procurement of integral tank sealants and one type of Buna-N topcoat (Slosh Coat). Example source and part numbers are provided in Appendix D, however any compliant sealant from any source is acceptable as long as the material is al l f rom the same lot and Cert i f icates of Conformance are included in the test report.

5.5. ADDITIONAL MATERIALS; NITRILE, FLUOROSILICONE, AND

FLUOROCARBON O-RINGS

In order to provide ini t ial screening information related to elastomeric compatibi l i ty, materials in the form of O-r ings are to be tested. This testing is in addit ion to the materials compatibi l i ty provided in ASTM D7826 and is useful for pre-screening. This test ing also provides data related to actual form and funct ion.

In order to faci l i tate the tests, each O-ring may be procured in two sizes. For example, each O-r ing may be procured as a -210 (1” OD) for use in compression set test ing and as a -226 (2 ¼” OD) for use in tensi le/elongation and hardness test ing. O-r ings in these two sizes provide for acceptable repeatabil i ty from the speci f ied test methods. Cert i f icates of Quali ty, Cert i f icates of Conformance or other documentat ions containing Lot information are to be requested and provided in f inal report. Materials specif ied are provided in Appendix E.

5.6. PAINT TEST

In order to provide information on the propensity of a fuel to cause staining or loss of adhesion, a matr ix of paint systems prepared to airworthy standards are required. For proper appl icat ion and adhesion, paints are described as systems, which may include any or al l of the fol lowing: a surface treatment, a primer, a base coat, and a clear coat. In a system, the dif ferent materials are not automatical ly interchangeable. Using unmatched components often inval idates the

27 | P a g e manufacturer’s warrantees or guarantees. To assure proper applicat ion of the systems, a professional faci l i ty capable of applying paint is recommended.

The paint systems as specif ied by the test plan are shown in Appendix F. Note that for the paint systems provided, the paint manufacturer l is ted is part of the requirements of the Material Test Plan. Each paint system is to be appl ied to 0.040” 2024-T3 aluminum per AMS-QQ-A-250/5B. The aluminum shal l be sheared into 5.08 cm x 10.16 cm (2” x 4” squares) prior to painting to avoid edge effects and damage to the paint by the shearing process.

In addit ion to the aircraft paint systems, compatibi l i ty of the coatings used on distr ibution fuel tanks must be considered. The coating systems are appl ied and tested in the same manner as aircraft paint systems. The distr ibution coat ing systems are provided in Appendix J.

5.7. FABRIC TEST

In order to provide information on the propensity of a fuel to cause loss of crossl inking, a loss of adhesion, or a loss of tensi le strength, a matr ix of fabric systems prepared to airworthy standards is required. For proper appl ication and adhesion, fabrics are described as systems, which may include any or al l of the fol lowing: the fabric, a surface treatment, a cement, and a coating. In a system, the dif ferent materials are not automatical ly interchangeable. Using unmatched components often inval idates the manufacturer’s warrantees or guarantees. To assure test ing of the fabric system specif ical ly, the test art icles do not include a f inal paint layer. This provides testing of the fabric system i tself and is indicat ive of unpainted regions, such as inter ior surfaces.

The fabric systems as specif ied by the test plan are shown in Appendix G. Note that for the fabric systems provided, the manufacturer l isted is part of the requirements of the Material Test Plan. Each fabric system is to be prepared by construction on an industry standard wooden test frame described below and shal l include a seam both attached and unattached to a support structure. The system shall be prepared to airworthy standards. None of the systems include any form of f inal paint which would confound the col lect ion of structural data.

5.8. DISTRIBUTION HOSES

In order to provide ini t ial screening information related to elastomeric compatibi l i ty of airport distr ibut ion hose, materials in the form of large diameter distr ibution hose are required. Hose test ing is designed to provide information on the propensity of a fuel to cause changes in physical response of the material to the fuel which is signif icantly dif ferent that that experienced when exposed to conventional ASTM D910 100LL aviation gasoline.

The hoses are procured as a 1 ½” minimum diameter hose. Either a regular or a defuel ing/Jac Riser hose may be used. The primary di f ference is the use of steel

28 | P a g e wire hel ix on the defuel ing hose; thus, a regular hose is preferred for the preparat ion of specimens. The hoses specif ied are provided in Appendix H.

5.9. COMPOSITE RESINS, ADHESIVES, AND FABRIC

In order to provide information related to the material compatibi l i ty of the resin systems used in general aviat ion aircraft , common resins, prepregs, adhesives, structural foam core, and fabrics are required. The l ist of materials is provided in Appendix I .

Composite testing is designed to provide information on the general compatibi l i ty of the composite systems but not specif ic material systems. The results can provide information on the propensity of a fuel to cause changes in structural propert ies which are signif icantly di f ferent than when exposed to conventional ASTM D910 100LL aviation gasol ine.

5.10. DISTRIBUTION FILTERS AND WATER SEPARATORS

In order to provide information related to the compatibi l i ty of distr ibut ion system fuel f i l ters and water separators, housings and cartr idges representative of those in use are required. Fi l ter/separator testing is designed to provide information on the propensity of the fuel to cause issues in the compatibi l i ty of the hardware;

both the housings and the consumable cartr idges, but not to assess the functional ity of the hardware with the fuel. Any assessment of the abi l i ty of the hardware to provide adequate funct ional i ty is beyond the scope of this effort.

The hardware is procured in the form of systems; a single element housing and the concomitant f i l ter/separator cartr idge. At the t ime of this wri t ing, water monitors comprised of super absorbing polymers have been removed from the market and are in the process of being replaced throughout the industry. Thus, water monitors are not specif ied in this document. Systems specif ied are shown in Appendix J.

5.11.

5.12. VENDOR SUPPLIED MATERIALS

In order to provide information related to the compatibi l i ty of individual materials specif ic to, and potential ly proprietary to individual original equipment manufacturers (OEMs), test ing of vendor suppl ied materials is desired. The parts include both sheet material and f inished parts.

The vendor suppl ied materials are ident if ied by and procured from the OEMs.

Materials are l isted in Appendix K.

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5.13. WING FUEL TANKS

In order to provide information related to the compatibi l i ty of wing tanks, part icular ly “wet wings”, representative of the tank sealants in use by air frame manufacturers, test ing of assembled wings is desired. Wing tank test ing is at the discretion of and under the purview of individual air frame manufacturers.

The hardware is identi f ied by and procured by the air frame manufacturers. No attempt to ident ify specif ic hardware is made within this guide.

6. DEFINITIONS & TERMINOLOGY

Definit ions, terminology and abbreviat ions specif ic to this document and to FAA nomenclature are summarized in the fol lowing sect ion.

6.1. EXPOSURE

Within this document, the term exposure is the placement of specimens in a test f luid at a given temperature for a given amount of t ime. Exposure also includes the applicat ion of test f luid to the surface of the fabric systems using a fuel reservoir and a cotton cloth.

6.2. CALIBRATION

Calibration is a set of actions that establ ishes that the instrument being cal ibrated is equal to or reports values equal to a standard.