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Abstract
Purpose – The study aimed to investigate epoxy composites reinforced with mechanical performances, thermal decomposition and ignitibility of
natural fiber (NF) and doped with 5 wt.% of varying flame-retardant (FR) compounds. The incorporation of ammonium polyphosphate (APP) and
zinc borate (ZB) showed improvement in modulus and elongation to break compared to the empty fruit bunch-filled epoxy (control). However, slightly
lower tensile and impact strengths were recorded in all FR-containing composites.
Downloaded by Hebei University of Engineering At 18:15 19 September 2016
Design/methodology/approach – Among the FR-loaded specimens, enhancement in flexural property was observed in composites with APP,
whereas the addition of ZB and alumina trihydrate (ATH) resulted in the reduction of flexural strength. Thermogravimetric analysis results
indicated that the introduction of APP and ATH negatively impacted the thermal degradation temperature (T d) of the NF-filled composites.
Greater mass residue with FR-filled composites, where increment was in the range from 32-80 per cent compared to the control, was observed,
with the greatest being the ZB-containing formulation. Vertical Bunsen burner experiment revealed that the addition of ZB and APP led to a zero
dripping flame system, whereas such a phenomenon was absent in both the control and NF composites loaded with ATH. The bomb calorimeter
results revealed that addition of NF into neat epoxy significantly enhanced the FR behavior of the composite, and the gross heat of combustion
was greatly reduced when FRs were incorporated into the control sample.
Findings – Results from the current study concluded that non-halogenated FRs including APP, ZB and ATH were able to enhance the fire retardancy
of EFB epoxy composite without significantly deteriorate the mechanical behaviors.
Originality/value – It can be shown from scanning electron microscopy micrographs that the fabrication technique produced composites with good
interfacial adhesion between NF and epoxy matrix, and homogenous distribution of FRs were achieved.
Keywords Epoxy, Flammability and mechanical properties, ATH, APP, ZB, Palm fiber
Paper type Research paper
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Effects of organophosphorus and mineral based flame World Journal of Engineering
retardants Volume 13 · Number 3 · 2016 · 193–
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Effects of organophosphorus and mineral based flame World Journal of Engineering
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recommended by the manufacturer) was added to the
sonicated volume. The mixture was left to de-gas for 10
min prior to infusion.
A custom-built mold was used for the fabrication of the
FR EFB-filled epoXy composite. To obtain a flat top
specimen surface and uniform thickness, a cut to
dimension peel ply, infusion mesh, thin aluminum plate and
vacuum bagging were aligned in sequence on top of the
dried fiber mat such that a more even compression
pressure could be achieved during vacuum-assisted resin
infusion. An initial procedure was performed to ensure that
the system is leakage free, i.e. full vacuum condition could
be established; the catalyzed epoXy FR mixture was
infused into the mold, where the flow path of the mixture
was guided by a series of spiral tubing to achieve full
wetting of the dried fiber mat. Curing of the composite was
allowed for 24 h under ambient conditions (humidity and
temperature). The cured FR-filled EFB epo Xy composites
were removed from mold and cut into dedicated specimens
size for mechanical, thermal and combustion analyses.
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on a lab stand. A natural gas Bunsen flame was applied to 3.2 Thermal properties
the leading edge of the bottom specimen surface for a period of Thermogravimetric analysis (TGA) curves of the composites
12 s and then detached. The flame time, drip flame time and with varying formulation are depicted in Figure 3. The mass
final mass loss (%) were recorded. residue at 600°C and the thermal degradation temperature
(Td) corresponding to 50 wt.% mass loss, i.e. at peak DTG,
2.8 Characterization of morphological properties are shown in Table III.
A FEI Quanta 400F field emission scanning electron The composites were thermally stable up to
microscopy (FESEM) was used for the analysis of specimen approXimately 300°C where the main decomposition took
surface topography. The fractured surface of composite place. The ZB-loaded composite showed the best thermal
specimens was mounted upright, and scannings were properties relative to other FR-based composites and the
performed under accelerating voltage of 20 kV and low- control. In terms of the thermal degradation, it can be
vacuum environment. observed that the Td for ZB-containing composite increased
by about 4°C compared to the control. Furthermore, the
3. Results and discussions residual mass of ZB-loaded composite at 600°C was found to
3.1 Mechanical performances be approXimately 80 per cent greater than the control. The
results imply that the ZB additive is much superior in
The measured tensile strength, modulus and elongation to
enhancing thermal behavior of the composite at an elevated
break of the EFB-filled epoXy composites containing
temperature and is capable of forming a large quantity of
various types of FR are summarized in Table II.
residue. Such phenomena could be attributed to the formation
It can be observed that addition of ATH and APP FRs
of a glassy insulating layer, which dilutes combustible
resulted in a much reduced tensile strength, whereas the
gases, and also the reaction of ZB residue with hydroXyl
incorporation of ZB produced a relatively similar response
(OH) functional group of natural fiber, such as
with that of the control (i.e. composite without FR). The
hemicelluloses and celluloses, produces extra amount of water
percentage drop in tensile strength for ATH- and APP-
loaded
composites was approXimately 19 and 21 per cent, vapor, which contributes to the improved char formation
respectively. Typical with additives, the inclusion of FR into (Khelfa et al., 2008).
polymeric matrices generally resulted in deterioration of the Overall, the residue attained increased with the
tensile performances, which can be attributed to the weakened incorporation of FRs relative to the control. ATH and APP
mechanical interlocking between the EFB and epo Xy matrix as generate alumina (metal oXide) and ammonia (phosphoric
a consequence of the present of FR (Kurt and acid), respectively, throughout their reactions with EFB
Mengelog˘lu,
2011; Shen et al., 2008). However, such an effect appeared to and epoXy resin, leading to the formation of a charred
be less significant with ZB. The measured modulus and barrier layer against thermal decomposition, insulting the
elongation to break indicated that E/APP and E/ZB substrates (Bourbigot et al., 2006). Neat EFB fiber showed
formulations tend to produce much higher values compared to a large amount of residue, mainly because of the presence of
E/ATH and the control. lignin constituents that are highly thermally stable, and
Table II Tensile properties of EFB-filled epoxy composites with ATH, APP and ZB
Sample Tensile strength (MPa) Modulus (GPa) Elongation to break (%)
EFB/E 32.62 2.53 4.05
E/ATH 26.39 2.42 3.87
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E/APP 25.60 3.12 4.33
E/ZB 31.26 3.13 5.62
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favorable to fire retarding performance. The enhanced
fire retardancy could be related to the shielding char layer
formed
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by the presence of ATH, APP and ZB. ATH and ZB is 3.4 Combustibility properties
capable of producing metal oXide, whereas APP forms The tensile fractured surfaces were subjected to scanning
phosphorous acid. In addition, the FR investigated in the electron microscopy (SEM). The SEM micrographs of the
current work has the tendency to generate water vapor from FR formulations are illustrated in Figure 6.
their thermal decomposition. Water absorbs the heat The image shown in Figure 6(a) revealed establishment of
released by combustion and reduces the amount of good bonding between EFB fiber and epoXy matrix.
flammable gases in the combustive zone, thereby improving Moreover, the micrographs in Figure 6(b-d) showed good
the formation of char. dispersion of ATH, APP and ZB within the epo Xy, which
indicated the good compatibility between FRs, EFB and
epoXy polymer.
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