1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2012 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR5774 AEROSPACE INFORMATION REPORT AIR5774 Issued 2012-12 Composite Fuel Tanks,
5、 Fuel System Design Considerations RATIONALE It has been discussed for quite some time that an industry standard is needed to outline the important considerations when developing the fuel system in a composite airplane and/or composite structure that contains the fuel system. After much consideratio
6、n, an industry working group was formed to develop this AIR. This industry working group consisted of members from major airframers, system suppliers, component manufacturers, and government agencies. FOREWORD This report is intended to give guidance for the design of modern fuel systems within the
7、context of composite fuel tanks. It is a compilation of industry references and best practices regarding fuel system design and composite structure. SAE AIR5774 Page 2 of 47 TABLE OF CONTENTS 1. SCOPE 4 1.1 Purpose . 4 1.2 Background . 4 1.3 Field of Application 4 2. REFERENCES 4 2.1 Applicable Docu
8、ments 4 2.1.1 SAE Publications . 4 2.1.2 ASTM Publications 5 2.1.3 FAA Publications . 5 2.1.4 U.S. Government Publications 5 2.1.5 Other Publications . 5 2.2 Related Publications . 6 2.2.1 SAE Publications . 6 2.2.2 ASTM Publications 6 2.2.3 FAA Publications . 7 2.2.4 U.S. Government Publications 7
9、2.2.5 Other Publications . 7 2.3 Definitions . 8 2.4 Acronyms and Abbreviations 9 3. DISCUSSION AND PREFERRED PRACTICES 10 3.1 Fuel Types 10 3.1.1 Summary of Jet Fuel Grades 10 3.1.2 Fuel Additives 12 3.1.3 Future Fuels 12 3.2 Materials 13 3.2.1 Characteristics 13 3.2.2 Considerations 14 3.2.3 Obsol
10、escence . 15 3.3 Corrosion . 15 3.3.1 Weathering 15 3.3.2 Cavitation 15 3.3.3 Galvanic and Dissimilar Materials . 15 3.3.4 Microbes 16 3.3.5 Surface Treatments and Coatings 17 3.4 Electromagnetic Effects (EME) . 17 3.4.1 Lightning Compatibility 18 3.4.2 High Intensity Radiated Field (HIRF) 22 3.4.3
11、Electro Magnetic Interference (EMI) . 23 3.4.4 Electrostatics . 23 3.4.5 Implementation Considerations 24 3.5 Fault Current . 25 3.6 Sealing 25 3.6.1 Permeability 25 3.6.2 Leakage 26 3.6.3 Micro-Cracking 26 3.6.4 Sealing for Penetrations 26 3.6.5 Material Compatibility 26 3.6.6 Thermal Expansion . 2
12、6 3.6.7 Preservation 26 3.6.8 Glass Transition Temperature 26 3.7 Component installation considerations . 26 3.7.1 Transport Elements . 27 3.7.2 Components, Line Replaceable Units (LRUs) 28 3.7.3 Tank Wire Harnesses (TWH) 28 SAE AIR5774 Page 3 of 47 3.8 Structural Considerations 28 3.8.1 Operating P
13、ressures . 29 3.8.2 Tank deflections 30 3.8.3 Fuel Quantity Indicating System (FQIS) . 31 3.8.4 Transport Element/Coupling Flexibility . 32 3.8.5 Penetrations 32 3.8.6 Required flow area 33 3.8.7 Unusable fuel 33 3.8.8 Component support and attachment 33 3.8.9 Access Provisions . 34 3.9 Durability a
14、nd Damage Tolerance 34 3.9.1 Maintenance Considerations 34 3.9.2 Damage Tolerance/Impact Resistance . 34 3.9.3 Rotor Burst 38 3.9.4 Crash load survivability . 38 3.9.5 Inadvertent Ejection 38 3.9.6 Ballistic survivability 38 3.9.7 Explosion Containment . 38 3.9.8 Fire Resistance . 38 3.9.9 Reparabil
15、ity . 38 3.10 Environmental Considerations 39 3.10.1 Contamination . 39 3.10.2 Temperature 40 3.11 Testing 42 3.11.1 Structural Testing 42 3.11.2 Proof Pressure and Leakage 42 3.11.3 System Functional Testing 42 3.11.4 EME Testing 42 3.11.5 Component Testing . 43 3.11.6 Electrical Bonding . 43 3.12
16、Fuel Tank Ullage Flammability 43 3.12.1 Flammability Background 43 3.12.2 FAA and EASA Fuel Tank Flammability Exposure Requirements . 44 3.12.3 Effects of Composite Structure on Fuel Tank Ullage Flammability 45 3.12.4 Military/General Aviation Applications 45 3.13 Ignition Prevention 46 4. NOTES 47
17、FIGURE 1 POINT IMPACT - INNER SKIN DAMAGE EXAMPLE 36 FIGURE 2 FLAT IMPACT - FORK LIFT/STORAGE RACK DROP DAMAGE . 36 FIGURE 3 LARGE BROAD IMPACT LOADING AND UNLOADING FLAT DROP DAMAGE . 37 FIGURE 4 LOADING AND UNLOADING ROTATED DROP DAMAGE 37 SAE AIR5774 Page 4 of 47 1. SCOPE This SAE Aerospace Infor
18、mation Report (AIR) is a compilation of engineering references and data useful to the technical community that can be used to ensure fuel system compatibility with composite structure. This AIR is not a complete detailed design guide and is not intended to satisfy all potential fuel system applicati
19、ons. Extensive research, design, and development are required for each individual application. 1.1 Purpose This document is intended to serve as guidance to airframe and equipment manufacturers for the design and installation of fuel systems into composite structure. This document is not intended to
20、 be a fully definitive specification, but concentrates on areas where it is felt guidance is needed. The purpose of this AIR is to compile one definitive source of the references, rules, regulations, and preferred practices for the development of a fuel system in composite structure. This AIR sets f
21、orth some useful design considerations for work with composites as it relates to the fuel system. 1.2 Background The development and installation of a fuel system in composite structure introduces a variety of design situations which are different from aluminum. The differences are related to the pr
22、operties of the composite material. As an example these may include low electrical and thermal conductivity, greater design sensitivity to penetrations, reduced shielding from electromagnetic radiation, reduced conductivity of lightning, and potential corrosion in graphite aluminum interfaces. 1.3 F
23、ield of Application This AIR applies to the aerospace industry and specifically to aircraft that use common petroleum fuels. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply
24、. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable la
25、ws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. AIR1662 Minimization of Electrostatic Ha
26、zards in Aircraft Fuel Systems AIR5128 Electrical Bonding of Aircraft Fuel System Plumbing Systems ARP5412 Aircraft Lightning Environment and Related Test Waveforms ARP5414 Aircraft Lightning Zoning ARP8615 Fuel System Components: General Specification For SAE AIR5774 Page 5 of 47 2.1.2 ASTM Publica
27、tions Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM D1655 Standard Specification for Aviation Turbine Fuels ASTM D6615 Standard Specification for Jet B Wide Cut Aviation Turbine Fuel 2.1.3 FAA Publicat
28、ions Available from Federal Aviation Administration, 800 Independence Avenue, SW, Washington, DC 20591, Tel: 866-835-5322, www.faa.gov. AC 25.981-1C Advisory Circular, Fuel Tank Ignition Source Prevention Guidelines AC 25.981-2A Advisory Circular, Fuel Tank Flammability CFR 25.981 Fuel Tank Ignition
29、 Prevention 2.1.4 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, https:/assist.daps.dla.mil/quicksearch/. MIL-STD-461F Requirements for the Control of Electromagnetic
30、 Interference Characteristics of Subsystems and Equipment MIL-STD-464 Electromagnetic Environmental Effects, Requirements for Systems MIL-STD-810 Environmental Test Methods and Engineering Guidelines 2.1.5 Other Publications AC/AMJ 20-53B Protection of Airplane Fuel Systems Against Fuel Vapor Igniti
31、on Due to Lightning CAN/CGSB 3.23 Aviation Turbine Fuel (Grades JET A and Jet A-1) DEF STAN 91-91 Turbine Fuel, Kerosine Type, Jet A-1 NATO Code: F-35 Joint Service Designation DERD 2494 Turbine Fuel, Aviation Kerosine Type, Jet A-1 NATO Code: F-35 Joint Service Designation RTCA DO-160F Environmenta
32、l Conditions and Test Procedures for Airborne Equipment STAS5639/88 Romanian Fuels, TH and T-1 Fuel grades SAE AIR5774 Page 6 of 47 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Aerospace Technical Report. 2.2.1
33、 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. ARP4043 Flight Line Grounding and Bonding of Aircraft AIR4069 Sealing of Integral Fuel Tanks ARP5413 Certificat
34、ion of Aircraft Electrical/Electronic Systems for the Indirect Effects of Lightning ARP5416 Aircraft Lightning Test Methods ARP5577 Aircraft Lightning Direct Effects Certification ARP5583 Guide to Certification of Aircraft in a High-Intensity Radiated Field (HIRF) Environment AMS3279 Sealing Compoun
35、d, Sprayable for Integral Fuel Tanks and Fuel Cell Cavities, For Intermittent Use to 350 F (177 C) AMS-C-27725 Coating, Corrosion Preventative, for Aircraft Integral Fuel Tanks for Use to 250 F (121 C) AMS-S-4383 Sealing Compound, Topcoat, Fuel Tank, Buna-N Type AMS-S-7124 Sealing Compound, Polysulf
36、ide, Accelerator Required, for Aircraft Structures AMS-S-29574 Sealing Compound, Polythioether, for Aircraft Structures, Fuel and High Temperature Resistant, Fast Curing at Ambient and Low Temperatures Pridham, B., Jaeger, D., and Schreiner, M., “Integral Lightning Strike Protection of CFC Fuel Tank
37、s on Aircraft,“ SAE Technical Paper 2001-01-2912, 2001, doi:10.4271/2001-01-2912 2.2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM D4154 Standard Practice for Evaluating the Compati
38、bility of Additives with Aviation-Turbine Fuels and Aircraft Fuel System Materials ASTM D6469 Standard Guide for Microbial Contamination in Fuels and Fuel Systems ASTM D910 Standard Specification for Aviation Gasoline SAE AIR5774 Page 7 of 47 2.2.3 FAA Publications Available from Federal Aviation Ad
39、ministration, 800 Independence Avenue, SW, Washington, DC 20591, Tel: 866-835-5322, www.faa.gov. AC 20-136A Protection of Aircraft Electrical/Electronic Systems Against the Indirect Effects of Lightning FAA-RD-73-98 Guidelines for Lightning Protection of General Aviation Aircraft 2.2.4 U.S. Governme
40、nt Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, https:/assist.daps.dla.mil/quicksearch/. AFFDL-TR-79-3047 Aircraft Integral Fuel Tank Design Handbook AFWAL-TR-81-4007 Manufacturing
41、 Methods for Adhesively Sealed Integral Fuel tanks AFWAL-TR-83-3114 Survivable Aircraft Fuel System Engineering Design Guide (SAFE/DG) JSSG-2009 Air Vehicles Subsystems JSSG2009 App. E Joint Service Specification Guide, Fuel System MIL-B-5087 Bonding, electrical and Lightning Protection, Aerospace S
42、ystems MIL-C-27725 Coating, Corrosion Preventive, for Aircraft Integral Fuel Tanks MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8) and NATO F-35 MIL-STD-1568 Materials and Processes for Corrosion Prevention and Control MIL-STD-882 System Safety Program Requirements MIL-T-2742
43、2 Tank, Fuel, Crash Resistant, Aircraft (Non-Self-Sealing and Self-Sealing) MIL-T-5578 Tank, Fuel, Aircraft, Self Sealing MIL-T-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 2.2.5 Other Publications AC/AMJ 20-53B Protection of Airplane Fuel Systems Against Fuel Vapor Ignition Due to Lightning EU
44、ROCAE ED-107 HIRF Users Guide GB 6537-94 Chinese Fuels, National Technology Supervisory Bureau, August 1994, Updated 1 June 1995 GOST 10227-86 Russian Fuels, Jet Fuel Specifications, Prepared by the State Standards Committee of the USSR, 1987, Updated August 1995. (CMEA Standard 5024 - 85)PRC Lightn
45、ing protection of aircraft Franklin Fisher and Anderson Plumer and published by Lightning Technologies Microbes Hazards to Space Missions from Microbial Biofilms By: R. Mitchello, and Ji-Dong Gu DECHMA Monographs Vol. 133 - 1996 SAE AIR5774 Page 8 of 47 RTCA DO-160F Environmental Conditions and Test
46、 Procedures for Airborne Equipment STAS5639/88 Romanian Fuels, TH and T-1 Fuel grades 2.3 Definitions BONDING SURFACE: The conductive surface of structure, part, or component which is to be electrically bonded to. CAPACITOR: Capable of accumulating and holding electric charge. COMPOSITE: A series of
47、 layers of filaments/fibers/fabrics of one or more materials bonded or embedded in an essentially homogeneous, resinous matrix, such as an epoxy matrix. CONDUCTOR: A material capable of carrying an electrical current. DIELECTRIC: A substance with negligible electrical conductivity. DIELECTRIC STRENG
48、TH: The maximum electric field strength that a material can withstand intrinsically without experiencing failure of its electrical insulating properties. DIELECTRIC WITHSTAND VOLTAGE: See dielectric strength. ELECTRICAL BOND: A fixed union between two objects that results in electrical conductivity
49、between those objects. ELECTRICAL BONDING: Connecting two or more conductive surfaces to form an electrically conductive joint. ELECTRICAL GROUND: An electrically conductive return path from equipment to structure. ELECTRICAL PERMITTIVITY: The ratio of the electric displacement in a medium to the electric field strength. Sometimes referred to as the dielectric constant. FAULT CURRENT: A higher than normal current flowing in a circuit resu
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