14 CFR Part 25-603 -

Materials – Blog Post

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Author: Surya Batchu

Senior Stress Engineer

Founder, STRESS EBOOK LLC.

http://www.stressebook.com

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Materials
In this post, we will dig into the next regulation, 14 CFR Subpart C Section 25-603 - Materials. Its
all about quality, material quality is critical to safe and long lasting aerospace structures.

§ 25.603 - Materials

The suitability and durability of materials used for parts, the failure of which could adversely affect safety,
must—

(a) Be established on the basis of experience or tests;

(b) Conform to approved specifications (such as industry or military specifications, or Technical Standard
Orders) that ensure their having the strength and other properties assumed in the design data; and

(c) Take into account the effects of environmental conditions, such as temperature and humidity,
expected in service.

[Doc. No. 5066, 29 FR 18291, Dec. 24, 1964, as amended by Amdt. 25-38, 41 FR 55466, Dec. 20 1976;
Amdt. 25-46, 43 FR 50595, Oct. 30, 1978]

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In the previous posts, we looked at:

 14 CFR Subpart C Section 25-301: Loads

 14 CFR Subpart C Section 25-303: Factor of Safety
 14 CFR Subpart C Section 25-305: Strength and Deformation
 14 CFR Subpart C Section 25-307: Proof of Structure
 14 CFR Subpart C Section 25-365: Pressurized Compartment Loads
 14 CFR Subpart C Section 25-561: General Emergency Landing Ultimate Loads
 14 CFR Subpart C Section 25-562: Emergency Landing Dynamic Loads
 14 CFR Subpart C Section 25-601: Hazardous Unreliable Design Features

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So much rides on this regulation. It is probably fair to say that the entire path to certification hinges
on compliance with this one regulation.

Let me explain what I mean...

(a) Materials - Statistical Basis & Test Data

Aerospace material applications are heavy on process specifications approved by the FAA, and
strength values developed based on extensive FAA approved testing, as well as actual fleet flight
experience. One of the most commonly used documents in this regard is MMPDS (Metallic
Materials Properties Development and Standardization). We discussed in detail about the tables in
this critical document, learn more about A-Basis and B-Basis allowable values.

Figure 1: Typical MMPDS Mechanical Properties Table, 2024 Plate

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If a part is made from a material listed in MMPDS, and the various material strength, temperature
dependency and fatigue data found in this document is strictly followed in sizing the components,
then the path to certification is that much more simple with the FAA.

The point here is that materials used in aerospace applications must have very well established
strength, durability, and process specifications, with supporting test data for a clear path to
certification and use in aerospace applications. WHY? SAFETY...... that is the cardinal rule.

Let us say you are an adventurist, and you are about to embark on an expedition that you have
never been on before. How do you really feel safe about it? You guessed it, with the knowledge
of people who have already been there done that and documented everything about that adventure.

You researched it, understand it and make sure to implement every rule of it, and that is how the
FAA feels confident about products that come to its doors for certification as well. A manufacturer
than can consistently and diligently demonstrate this has a lot to gain and maintain.

(b) Materials - Approved Specifications

Aerospace grade materials must comply with stringent manufacturing process requirements. What
the heck does that mean?

In simpler terms, any aerospace part must be made from a material that complies with strict
manufacturing process standards acceptable for use in aerospace applications.

Figure 2: NAS Materials

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Per 14CFR 25.603(b), all structural materials and fasteners must conform to approved
specifications. For example, aluminum materials must be specified using Aerospace
Material Specifications (AMS) maintained by the Society of Automotive Engineers. Fasteners
must be specified using Army-Navy (AN), Military Specification (MS), and National Aerospace
Standard (NAS) specifications. If a material specification or fastener specification is used which
is not published by one of the organizations listed above (example: Hi-Loks) then that
specification must be approved by the respective ODA as a part of each project on which it is used.

Aerospace materials specifications include composition, statistical test data requirements, temper
data, tested strength data, among other important information. Any supplier is required to comply
with these requirements in order to be a certified supplier acceptable to the procurement
departments of aerospace manufacturers.

WHY? It is all about safety of you and me.

Humans without wings flying at 30,000 to 40,0000 feet above sea level, sitting in a seat inside a
pressurized barrel is unnatural and no joke.

It is serious business and extremely risky. And without quality materials helping us do that, it is
simply impossible.

(c) Materials - Environmental Effects

Is it enough to follow the specifications? Of course not.

Temperature effects, humidity effects, corrosion treatment (anodization) effects, static electricity,
sonic fatigue, pressure, mechanical vibration fatigue and many other considerations are required
for certification with the aerospace certifying authorities (example FAA, EASA etc.).

Let us consider the engine nacelle for example. If there is one part of the aircraft where
Armageddon shines, that is the engine nacelle and the engine itself. It is probably where the worst
of the worst conditions come together in perfect synergy, and where the first line of safe flight
defense begins.

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Environmental effects such as the impact of high temperature on the fatigue and durability of a
component, corrosion resistant anodization treatment of Aluminum parts etc. must all be accounted
for in the sizing of these parts.

The key to the critical path to certification (CPTC) for these conditions is the use of a material that
complies with all of these important regulations.

Learn more about how this regulation ties into the Proof of Structure regulation. Learn more
about A-Basis and B-Basis allowable values.

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