What is the Cargo Compartment Liner Burn-Through Fuel Test System?

The Cargo Compartment Liner Burn-Through Fuel Test System is a specialized aviation fire testing platform designed to evaluate burn-through resistance, flame spread behavior, and fuel fire performance of aircraft cargo compartment liners and related materials under controlled aviation fuel fire exposure. The system integrates the FAA-approved NexGen aviation fuel burner with a dedicated seat cushion test frame and dynamic loading motion system, enabling realistic simulation of aircraft fire scenarios while accurately controlling and monitoring fuel and air parameters. Its modular design supports current regulatory testing requirements and future FAA technical upgrades.

Application

This system is suitable for aviation fuel fire testing of a wide range of aerospace materials and components, particularly those used in aircraft interiors and cargo compartments, including:

Cargo compartment liner panels

Aircraft seat cushions

Composite sandwich panels

Cabin interior panels

Ceiling and sidewall liners

Fire barrier layers

Thermal and acoustic insulation assemblies

Multi-layer composite structures

The FAA-approved NexGen burner provides standardized aviation fuel flame exposure, while the seat cushion test frame and dynamic motion system allow direct evaluation of flame behavior, burn-through risk, and material performance under realistic fire conditions.

Standards

The system supports testing in accordance with the following international aerospace fire safety standards:

BSS 7303 – Combustion performance and flame spread behavior of aerospace composite materials

AITM 2.0009 – Determination of flame spread characteristics of aerospace materials

FAR Part 25 Appendix F Part II – Aircraft cabin material combustion, flame spread, and smoke toxicity requirements

Parameters

Features

1. The burner cone is made of a corrosion-resistant and high-temperature-resistant alloy.

2. The NexGen aviation fuel burner includes components such as a spoiler, fuel nozzle, igniter, fuel rail, mounting plate, ventilation duct and housing, muffler, and acoustic damper.

3. Equipped with a fuel pressure gauge, fuel solenoid valve, fuel temperature detection device, air pressure regulating valve, and air temperature detection device.

4. Equipped with an ice bath with a volume of at least 2 x 0.14 m³ for fuel and air temperature control, allowing for precise fuel temperature control.

5. Different testing standards can be met by changing the fuel nozzle and air pressure input.

6. The burner is covered with an insulating blanket to cover the fuel lines and fuselage.

7. The NexGen aviation fuel burner can provide a flame temperature of at least 2000±50℉.

8. The NexGen aviation fuel burner provides a flame heat flux of no less than 10.6 W/cm².

9. Modular unit using the NexGen burner support system.

10. Heavy-duty steel frame, capable of horizontal and vertical mounting of test samples.

11. Seven 1.6 mm diameter ceramic-encapsulated, metal-sheathed, grounded Type K (NiChC-NiA) thermocouples should be used for calibration. The conductors should have an outer diameter of 0.254 mm, a cross-sectional area of 0.0507 mm², and a resistance of 361 Ω/km (US wire gauge 30 AWG). The thermocouples should be fixed to an angle steel bracket to form a thermocouple comb for placement on the sample holder during calibration.

12. Thermal radiation flux sensor, equipped with a cooling device, mounted on a fixed bracket.

Accessories

The system is supplied with the following components:

NexGen aviation fuel burner

Seat cushion test frame

Dynamic loading motion system

Fuel temperature control ice bath

Thermocouple calibration comb

Radiant heat flux sensor with cooling unit

Powder-coated steel support frame with digital scale

Movable seat cushion test fixture

Movable drip collection tray

Burner thermal insulation blanket

Test Procedures

Mount the cargo liner panel or seat cushion specimen on the designated test frame.

Connect aviation kerosene supply and compressed air (≥120 PSI).

Set and stabilize fuel temperature using the ice bath system.

Adjust air pressure and fuel flow parameters according to the selected standard.

Ignite the NexGen burner and allow the flame to stabilize.

Position the flame relative to the specimen and initiate exposure.

Monitor flame temperature and heat flux using thermocouples and sensors.

Observe flame spread behavior, burn-through occurrence, and dripping characteristics.

Collect data, including temperature, heat flux, and material response.

Evaluate performance in accordance with the applicable standard.

Maintenance Information

To ensure long-term reliability and compliance:

Clean the fuel nozzle regularly to prevent blockage.

Inspect fuel lines and valves for leakage before each test.

Calibrate thermocouples and heat flux sensors periodically.

Replace the burner insulation blanket if damaged or degraded.

Maintain proper ventilation in the test area.

Keep the compressed air system dry and free from oil contamination.

Verify load cell calibration before critical certification tests.

Core Technical Advantages of the Cargo Compartment Liner Burn-Through Fuel Test System

The Cargo Compartment Liner Burn-Through Fuel Test System is designed to evaluate the flame penetration resistance of cargo compartment liner materials under simulated real aircraft fuel fire scenarios. Its core technical advantages are reflected in high fire integrity, low heat transfer, structural stability, and compliance with airworthiness certification standards.

High Fire Resistance and Thermal Insulation Performance

The system typically employs multi-layer composite structures, such as glass fiber reinforced layers, flame-retardant polymers, or metal-composite sandwich panels. Under standardized fuel fire exposure, the material can maintain burn-through resistance for over 10–30 minutes, while keeping the temperature rise on the non-exposed surface within safe limits (e.g., ≤180°C). This effectively prevents ignition of the cabin interior or critical onboard systems.

Self-Extinguishing and Carbonization Insulation Mechanism

Advanced liner materials may undergo controlled carbonization at high temperatures, forming a low-thermal-conductivity char layer. This char layer acts as a barrier that blocks heat transfer and prevents flame propagation, avoiding brittle failure caused by rapid burn-through. This mechanism provides superior performance compared to traditional metallic liners.

System Integration and Certification Compliance

The system is specifically designed for aviation and marine applications and supports standardized fuel fire sources along with controlled pressure and airflow simulation. This ensures high repeatability and traceability of test results, making it suitable for airworthiness certification and compliance with fire-resistance standards such as A-60 or equivalent ratings.

Lightweight Design and Structural Adaptability

Compared with full-metal solutions, composite liner systems can achieve a weight reduction of 30–50%, while maintaining excellent adaptability to complex curved cabin structures. Some advanced configurations also integrate fire detection interfaces or fire-suppression agent release channels, enabling coordinated active and passive fire protection.

Low Smoke Toxicity and Environmental Stability

The materials used meet strict smoke density and toxicity requirements under standards such as IMO MSC.1/Circ.1274 and FAA regulations. Additionally, the system maintains structural integrity under temperature, humidity, and pressure cycling conditions, including low-pressure high-altitude environments, preventing accelerated burn-through risks due to cabin depressurization.

Overall, the Cargo Compartment Liner Burn-Through Fuel Test System provides a highly reliable and standardized platform for evaluating fire resistance performance under extreme conditions, ensuring aviation safety, regulatory compliance, and advanced material validation for modern aircraft structures.