FAA/NASA Workshop on Composite Material Control

Mark Freisthler Allen Fawcett Rod Osborne August 2002

FAA/NASA Workshop on Composite Material Control

Boeing Material Qualification & Certification Philosophy

Established Methods, Processes and Specifications that ensure the engineering material requirements of the design are met with a high degree of confidence and reliability

FAA/NASA Workshop on Composite Material Control

General Boeing Requirements

Any set of Material/Process Specifications must:
Ensure the continued certification basis of a product Allow the product to be economically produced Permit limited modifications to account for local production conditions Be responsive to the companys changing requirements

FAA/NASA Workshop on Composite Material Control

What Industry Specifications Must Accomplish to Provide Value to Boeing

Lower cost Qualification/Certification of new materials Lower production cost Faster implementation time Commonality of specifications, methods and

processes, and database requirements Rapid response to user needs Enable global standardization of specification requirements
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FAA/NASA Workshop on Composite Material Control

Air Framers Considerations

Any new manufacturing technology must

have a stable and repeatable product Documented controls must be established The intended use of product has been identified Level of certification documentation has been identified
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FAA/NASA Workshop on Composite Material Control

Air Framers Concerns

Overly conservative design

values Inability to adapt to vendor unique circumstances Loss of product consistency over time Unknown variability of key mechanical properties

FAA/NASA Workshop on Composite Material Control

Design Value Basics

Design Values must reflect materials & processes

actually used in production Design Values do not control a product, but reflect the control placed on the product The analytical tools used in design dictate the parameters for which Design Values are derived Design Values must reflect actual in-use conditions
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FAA/NASA Workshop on Composite Material Control

Certification Balance
Premium Selection or Point Design Spec Controls and Allowables & Analysis Methods in Place Certification Requirements

Material & Process Specifications

Performance Goals

Methods & Allowables

OR
FAA/JAA Regulations

Testing Requirements Criteria

The more the materials and processes are under control and Methods & Allowables understood, the less testing is required for certification

FAA/NASA Workshop on Composite Material Control

Product & Design Connection

Manufacturing Processes

+
Material Purchased

=
Product

Manufacturing Processes

Material & Processing Standards

Material Specification

Process Specification

Engineering Processes

A B Prediction of Material Behavior

(Design Values)

+
Prediction of Structural Behavior
(Design Analysis)

+
Verification & Certification Tests

=
Certification Basis

Engineering Requirements & Standards

Published Design Manuals (Design Analysis & Allowables)

Arrows Denote Delivery Tools (Paper and/or Electronic)

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FAA/NASA Workshop on Composite Material Control

Compatibility Between Internal and External Documentation

End User Requirements

Internal Process Specification

The Proposed Bridge DOT AR-02 FAA XX Material Supplier Industry Specification
Material Specification

Process Used to Produce Test Parts

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