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Effects of organophosphorus and mineral

based flame retardants on combustibility


and mechanical performances of natural
fiber reinforced composites
Pooria Khalili, Kim Yeow Tshai and Ing Kong
Faculty of Engineering, Department of Mechanical, Materials and Manufacturing Engineering,
The University of Nottingham Malaysia Campus, Selangor, Malaysia

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.
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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

1. Introduction flame retardancy of composites has evolved as a crucial aspect


for fulfilling the safety specifications of the NF-based
The merits of using natural fiber (NF) as the reinforcing filler
products (Bakar et al., 2010). Among the many approaches
in polymeric matrices are that these bio-derived sources are
abundantly available; are sustainable, recyclable, economically available, one of the main strategies to improve flame
non-abrasive and of low density; and possess highly specific retardancy is to use flame-retardant (FR) compounds into the
performance to weight ratio (Bakar et al., 2010; Tshai et al., polymeric matrix or composite blend during fabrication
2014, 2015). Over the past decade, bio-based fiber-reinforced process. Halogenated FRs compounded with bromine and
polymer composites have been utilized in a wide array of chlorine are among the available additives. Nevertheless,
industries, including, but not limited to, the upholstery, these types of FRs are rarely used because of their menace to
automotive and food packaging (Rowell, 2006). the human and environment health. The variants of FRs
Nevertheless, the main disadvantage of NF-filled polymer most broadly applied to bio-based composites include
composites lies in its ease of ignitibility because the main mineral-based boron compounds, mainly borates (Sain and
constituents – NFs and polymeric matrices – show high Kokta, 1994; Sain et al., 1993) and metal hydroXide types,
flammability properties in nature. Therefore, enhancement in such as alumina trihydrate (ATH), (Sain et al., 2004; Wu et
the al., 1999) and those of organophosphorus-based compound,
such as ammonium polyphosphate (APP) (Li and He, 2004).
The current issue and full text archive of this journal is available on Boron-based FRs are less toXic and cheaper alternatives to
Emerald Insight at: www.emeraldinsight.com/1708-5284.htm antimony oXide (as a traditional FR) (Shen et al., 2008). Zinc

This work was supported in part by the Ministry of Science, Technology


World Journal of Engineering
13/3 (2016) 193–198 and Innovation (MOSTI), Malaysia, under Grant 03-02-12-SF0212 and
© Emerald Group Publishing Limited [ISSN 1708-5284] the Faculty of Engineering at The University of Nottingham Malaysia
[DOI 10.1108/WJE-06-2016-025] Campus.

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Effects of organophosphorus and mineral based flame World Journal of Engineering
retardants Volume 13 · Number 3 · 2016 · 193–

borates (ZBs) have been used as a smoke suppressant and an


FR compound for polymers, where the intrinsic flame Table I Composition of constituent materials
retardation function can be contributed through hindrance of Wt.%
oXygen’s entry to the underlying layers via the formation of Sample Epoxy EFB ATH ZB APP
a porous borate surface coating and water release (Nelson,
1990). APP on the other hand is capable of producing a E 100 – – – –
thermal shielding layer from its reaction with carbonaceous EFB/E 82 18 – – –
parts of the NF, leading to a retardation of further fire spread EFB/E/ATH 77 18 5 – –
(Samyn et al., 2007). Also, ATH, which is broadly used as E/ZB 77 18 – 5 –
a E/APP 77 18 – – 5
metal hydroXide FR, can enhance the fire retardancy by Notes: E = neat epoxy; EFB = empty fruit bunch fiber
liberation of water and formation of a protecting charred
layer upon combustion.
In the current work, three of the most widely used FRs – to 50 per cent. Stoichiometric amount of hardener (20 parts
ZB, APP and ATH – were incorporated into NF-filled hardener to 100 parts base epoXy resin by mass as
epoXy
composite, and their effects on the thermal–mechanical processor, operating at 20 kHz and the amplitude was tuned
properties and fire retardancy were investigated.
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2. Materials and methods


2.1 Materials
Pulverized oil palm empty fruit bunch (EFB) fibers with
average bundle diameter in the range of 100-200 µm and 10
mm in length were purchased from Szetech Engineering
Sdn. Bhd., Malaysia. APP phase II powder of trademark
EXolit AP 422 with degree of polymerization being more
than 1,000 was provided by Clariant (Singapore) Pte Ltd.
ATH with particle size in microns and ZB 400 with particle
size 3-5 µm were provided by J.M. Huber Corporation,
Malaysia branch. The matrix system, an ambient cure two-
part epoXy resin Ultimeg U2020, was supplied by AEV Asia
Sdn. Bhd., Malaysia. The epoXy/hardener mixture has a
specific viscosity of 1.1, and its viscosity at 25°C was
measured 0.2-0.6 Pa·s. The water based formaldehyde-free
crosslinked acrylate binding agent Acrodur DS 3,530 was
supplied by BASF Sdn. Bhd., Malaysia.

2.2 Preparation of fiber mats


Palm EFB fibers of 20 g were contained into a customized
rectangular sieve measuring 180 × 320 mm (length × width)
and then soaked in a mixture of water and Acrodur binder at
a 10:1 ratio. The sieve was gently vibrated to enhance fiber
distribution across the sieve, whereas the suspension was
mechanically stirred to enhance dispersion of the binding
agents in the aqueous medium. The wet fiber mat was taken
out from the water-binder suspension, and few minutes were
allowed for draining out the excess water. An assembly of
heavy metal plate, blotting papers and top load weighing of 10
kg was used to press out the remaining water. The fiber mats
were then kept for 24 h in an oven heated to 70°C to
eliminate the residual moisture.

2.3 Fabrication of FR-filled EFB epoxy composites


The FR and palm EFB-filled epoXy composite specimens
were prepared through vacuum resin infusion techniques.
Sonication was used to enhance the dispersion of the FR
microparticles in the epoXy matrix. The composition for
each of the constituent is given in Table I.
For FR-filled specimen, 5 wt.% of the three types of FRs
(ATH, ZB and APP) was separately added to the base epo Xy
resin, and the mixture was exposed to sonication for a period
of 15 min with the aid of Hielscher UP400S ultrasonic

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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.

2.4 Characterization of mechanical properties


A bench type tensile machine Lloyd Instruments LR50K
Plus was used to characterize the tensile and flexural
properties of the composites. The tensile and flexural
experiments were conducted in accordance to the ASTM
D3039/3039M and ASTM D790 standards, respectively. A
constant crosshead speed of 2 mm/min was applied to the
tensile specimens measuring 120 × 20 × 2 mm (length ×
width × thickness). Flexural samples having dimensions
100 × 20 × 2 mm (length × width × thickness) were
subjected to a uniform crosshead speed of 5 mm/min at
mid-point over a span length of 60 mm. The impact
strength was tested on rectangular specimens of 63.5 ×
12.7 × 2 mm in accordance to ASTM D6110 standard
with the aid of MH-358 Charpy Impact Tester. Three
samples from each material composition were tested and
the average value of the respective property was analyzed.

2.5 Characterization of thermal properties


A Mettler-Toledo simultaneous TGA/DSC 1 instrument
was used for characterization of the thermal properties.
Sample weighing of 10-15 mg placed within an open alumina
crucible was heated from room temperature to 600°C at a
constant 20°C/min ramp, and the assembly was maintained
under nitrogen environment supplied at 20 ml/min. Three
tests were performed for each formulation, and the
average thermal

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degradation curve (in percentage weight loss) plot against


temperature variation was analyzed. Figure 1 reveals the flexural properties of the composite
specimens. As observed, the inclusion of FR caused a negative
effect on the flexural behavior of the composites, where the
2.6 Characterization of combustibility properties
flexural strength and strain decreased for ATH- and ZB-
A bomb calorimeter PARR 6100 was used to characterize
filled composites, ascribed to the poor wettability of the epo Xy
the gross heat of combustion (GHC) of the composite
resin in the present of FR. However, the E/APP formulation
specimens in accordance to ASTM D-240 standard. The
demonstrated better flexural strength relative to other
dedicated fuse wire was positioned such as it touched the
formulations.
top surface of the solid specimen fragment for combustion to
The impact behavior of neat epoXy, EFB/E and FR-filled
occur. In all cases, a specimen fragment of less than 1 g
compositions are exhibited in Figure 2.
was used.
It can be seen that addition of EFB fibers provided a
reinforcing effect in terms of the impact strength of the
2.7 Characterization of flammability properties
composite contributed by the establishment of good interfacial
Vertical burn tests were set up in accordance with the
adhesion between the EFB fiber and epoXy resin. Inclusion
specification of Federal Aviation Regulation (FAR) 25.853
of FRs however reduced the impact strength; in general,
12s vertical burn test standard. Rectangular specimen
the FR filler disturbed the epoXy continuity, acting as a
equivalent to half of the standard FAR dimension,
stress-concentrated site, and as a result, prone to the
measuring
initiation of micro-crack (Mareri et al., 1998).
152.5 × 37.5 × 2 mm, were vertically suspended by a clamp
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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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Figure 1 Flexural behavior of the composites


Figure 4 Bunsen burner test observations of the composite
specimens

their thermal decomposition resulted into a large quantity


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Figure 2 Impact behavior of the composites of char residual.

3.3 Combustibility properties


Figure 4 exhibits the observations from the vertical Bunsen
burn tests, which provide further qualitative observations of
fire spread and pyrolysis on the composites.
The results showed comparable mass loss pattern to that
of the TGA for FR-filled composites, where ZB followed by
APP-loaded composites demonstrated higher mass residue
relative to the ATH containing formulation. With regard to
the drip flame time, ZB- and APP-based compositions did
not generate any dripping, whereas ATH and EFB/E
recorded dripping for approXimately 25 and 55 s,
respectively. This indicated that ZB and APP provide
greater effect on reducing ignitibility behavior of the EFB
Figure 3 TGA curves of the composites
epoXy composites. ATH-filled composite was observed to
burn more rigorously than other FR-based samples, where
an approXimately 4 min flame time and dripping were
recorded, suggesting that ATH is poorer in restricting the
liberation of flammable gases during the event of fire.
Furthermore, APP- and ZB-loaded composites maintained
the physical integrity and shape throughout the
combustion, whereas the control and ATH-containing
samples experienced shrinkage and warp, resulting in the
loss of their original structure.
The large drip flame time for EFB/E was owing to an
increasingly deteriorating NF network, which was not
protected by the dilution of ignitable oXidizable gases via
ZB and APP-containing formulations. This resulted in
extensive pyrolysis of the EFB/E sample and consequently
accelerated the burning progression, increasing the dropped
parts.
Table III Thermogravimetric analysis (TGA) data under nitrogen The flammability behaviors were also investigated with a
atmosphere bomb calorimeter instrument, where gross heat release and
fire decomposition were analyzed. Figure 5 showed the
GHC of the formulation with varying FR additives.
The neat epoXy specimen E100 demonstrated the highest
Sample name Char residual at T600 (wt.%) Td (°C) GHC owing to its inherent nature to flammability. Addition of
EFB/E (control) 15.56 385.87 EFB fibers into epoXy significantly dropped the GHC from
E/ATH 20.47 383.37 about 35 to 31.8 MJ/kg.
E/APP 21.41 376.784 Incorporation of FRs had a considerable positive effect of
E/ZB 27.92 389.49 reducing the GHC of the EFB epoXy composites, which is
Nest EFB fiber 30.72 346.864

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Effects of organophosphorus and mineral based flame World Journal of Engineering
retardants Volume 13 · Number 3 · 2016 · 193–
favorable to fire retarding performance. The enhanced
fire retardancy could be related to the shielding char layer
formed

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Effects of organophosphorus and mineral based flame World Journal of Engineering
retardants Volume 13 · Number 3 · 2016 · 193–

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.

Figure 5 Gross heat of combustion 4. Conclusions


Results from the current study concluded that non-
halogenated FRs, including APP, ZB and ATH, were able to
enhance the fire
retardancy of EFB epoX composite without significantly
y
deteriorating the mechanical behaviors. The tensile strength
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of ATH- and APP-loaded composites were reduced by


approXimately 19 and 21 MPa, respectively, in comparison
with the neat EFB epoXy composite (control), whereas
elongation at break and modulus were improved with the
addition of APP and ZB particles. The flexural and impact
strength of FR-based composites seem to reduce compared
to the control, with the exception for the APP-containing
sample, which was found to experience enhancement by
around 35 per cent. The reason for such improvement merit
further investigation.

Figure 6 SEM micrograph of the composites

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Effects of organophosphorus and mineral based flame World Journal of Engineering
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Upon the event of fire, the char formed among EFB, FR


and epoXy was found capable of inhibiting the mass and Rowell, R.M. (2006), “Advances and challenges of wood
heat transfer into the bulk of the substrate, leading to larger polymer composites”, paper presented at the Proceedings of
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Pooria Khalili can be contacted at: pooria.khalili@gmail.com

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