EPDM based heat shielding materials for Solid Rocket Motors: A comparative study of different fibrous reinforcements

EPDM/aramid ablatives represent the state of the art heat shielding materials for Solid Rocket Motors. Due to their mechanical properties and excellent thermal stability, aramid fibers or pulp constitute the common reinforcement of EPDM based liners. New generation organic fibers were recently tested as a potential replacement of aramid. In this study, Kynol fiber, a phenolic based reinforcement with high mechanical and thermal properties, was evaluated on this class of ablatives: to date, there are no data available on the use of Kynol fibers in EPDM based ablatives. At the same time, silica fibers which are traditionally used on other classes of ablatives, were also tested: in fact, the use of this type of reinforcement is not well documented on EPDM ablatives. It was found that EPDM/Kynol composition produced the char with the smaller dimensional change and the higher adhesion on the virgin material. EPDM/aramid exhibited the higher insulation properties. At the studied fiber percentage, EPDM/silica showed the worst behavior than the other formulations. The obtained data improved the comprehension of the role of the different fibers on the ablation mechanism of this class of ablatives, thus enabling the possibility to exploit their intrinsic properties.     

Property correlations for composites based on ethylene propylene diene rubber reinforced with flax fibers

EPDM composites filled with short flax fibers were prepared by melt blending procedure. The effects of fiber loading on the mechanical, thermal and water uptake characteristics were studied. The physico-mechanical, morphological thermal properties and water absorption behavior were discussed using tensile testing, differential scanning calorimetry, thermogravimetrical analysis and scanning electron microscopy. Scanning electron microscopy revealed that the flax fibers were well dispersed in the polymer matrix. The tensile strength and hardness of the composites were found to be improved at higher fiber loading. The water absorption pattern of EPDM/fiber composites at room temperature follows a Fickian behavior for composites with 10, 15 and 20 phr flax fiber.     

Studies on the properties of EPDM–CSE blend containing HTPB for case‐bonded solid rocket motor insulation

Elastomeric blends based on ethylene propylene diene (EPDM) rubber as a primary polymer have been investigated for the thermal insulation of case‐bonded solid rocket motors (SRMs) cast with composite propellant containing hydroxy terminated polybutadiene (HTPB) as a polymeric binder. EPDM rubber found as an attractive candidate for the thermal insulation of case‐bonded SRM due to the advantages such as low specific gravity, improved ageing properties, and longer shelf life. In spite of these advantages, EPDM, a non‐polar rubber, lacks sufficient bonding with the propellant matrix. Bonding properties are found to improve when EPDM is blended with other polar rubbers like polychloroprene, chlorosulphonated polyethylene (CSE), etc. This type of polar polymer when blended with EPDM rubber enhances the insulator‐to‐propellant interface bonding. In the present work, an attempt has been made to study the properties of EPDM–CSE based insulator by incorporating HTPB, a polar polymer as well as a polymeric binder, as an additive to the EPDM–CSE blend by varying the HTPB concentration. Blends prepared were cured and characterized for rheological, mechanical, interface, and thermal properties to study the effect of HTPB addition. This paper reports the preliminary investigation of the properties of EPDM–CSE blend containing HTPB, as a novel and futuristic elastomeric insulation for case‐bonded SRM containing HTPB as propellant binder. Copyright © 2007 John Wiley & Sons, Ltd.     

Free radical photopolymerization process for fiber‐reinforced polymer: Effect on the mechanical properties

Glass–fiber‐reinforced polymers were manufactured either through a room temperature thermal curing or under ultraviolet (UV) light from a LED. The thermal system yields high performances when a post‐curing process at 65°C is applied. The photochemical curing leads to a composite in a faster timescale, albeit at the extent of the mechanical properties. It is found that in this case, impregnation and vacuum steps are too fast to allow a good wetting of the fibers, thereby leading to mechanical weaknesses and larger void volume. However, when applying longer vacuum and impregnation steps, the mechanical properties of the photochemically cured sample match the best thermally cured one. As a conclusion, it is shown that photochemical curing of glass–fiber‐reinforced polymer can lead to high performance composite provided that the preparation steps are well controlled.     

Effects of UV irradiation on physico‐mechanical properties of EPDM/buckminsterfullerene composite

Ethylene propylene diene rubber‐fullerene (EPDM/C60) composite, partially crosslinked by ultraviolet (UV) radiation, was prepared and characterized for crosslink density, mechanical properties and thermal behavior. FT‐IR analysis showed peak disappearance at 1688 cm^?1, corresponding to the unsaturation of EPDM, and the appearance of new peaks relating to the formation of oxidation products of C60, such as epoxide, keto, aldehyde and carboxylic groups. Solubility studies demonstrated the dissolution of pristine EPDM in toluene even after a longer period of UV exposure, whereas EPDM/C60 composite became insoluble and/or swollen after 6 hr of UV exposure, indicating the formation of partial crosslinking between EPDM and C60. Differential scanning calorimetry (DSC) measurements revealed an increase in the glass transition temperature peak of UV‐cured EPDM. Thermogravimetric analysis (TGA) showed that UV exposure reduced the thermal decomposition temperature of EPDM/C60, pristine EPDM and dicumyl peroxide (DCP)‐cured EPDM. The modulus, tensile stress and elongation at break of EPDM/C60 composites were greatly influenced by the duration of UV irradiation. Comparison of UV‐cured EPDM/C60 composite with DCP‐cured EPDM confirmed the superior strength properties of the former system. Copyright © 2004 John Wiley & Sons, Ltd.     

Mechanical properties of rigid polyurethane composites reinforced with surface treated ultrahigh molecular weight polyethylene fibers

The mechanical properties of ultrahigh molecular weight polyethylene (UHMWPE) fibers reinforced rigid polyurethane (PU) composites were studied, and the effects of the fiber surface treatment and the mass fraction were discussed. Chromic acid was used to treat the UHMWPE fibers, and polyurethane composites were prepared with 0.1 to 0.6 wt% as‐received and treated UHMWPE fibers. Attenuated total reflection Fourier transform infrared demonstrated that oxygen‐containing functional groups were efficiently grafted to the fiber surface. The mechanical performance tests of the UHMWPE fibers/PU composites were conducted, and the results revealed that the treated UHMWPE fibers/PU composites had better tensile, compression, and bending properties than as‐received UHMWPE fibers/PU composites. Thermal gravimetric analyzer showed that the thermal stability of the treated fiber composites were improved. The interface bonding of PU composites were investigated by scanning electron microscopy and dynamic mechanical analysis, and the results indicated that the surface modification of UHMWPE fiber could improve the interaction between fiber and PU, which played a positive role in mechanical properties of composites.     

Extraction and characterization of alkali-treated red coconut empty fruit bunch fiber

This article discusses the extraction and characterization of new natural fiber extracted from red coconut empty fruit bunch. The physicochemical, mechanical, and thermal properties of alkali-treated red coconut empty fruit bunch fibers (ARCEFBFs) were reported and compared with other natural fibers for the first time. Cellulose content (65.02 wt%), wax (0.32 wt%), density (1.421 g/cc), and tensile strength (1299.49 MPa) were identified in ARCEFBFs. Fourier transform infrared spectroscopy and X-ray diffraction analysis confirmed that ARCEFBFs are rich in cellulose content with crystallinity index of 53.6%. Thermogravimetric analysis revealed that these fibers are thermally stable until 270.48°C.     

Reactive Nanocomposites as Versatile Additives for Composite Propellants

A new approach to improve the performance of composite propellants was developed in which reactive nanocomposites (RNCs) are used as replacements for aluminum powders in composite solid rocket propellants. The new materials are mechanically activated nanothermites comprising of nano‐powders of aluminum as the fuel as well as oxides of copper, iron, molybdenum, or nickel as the oxidizer. The obtained RNCs were characterized using X‐ray diffraction, scanning electron microscopy, and laser diffraction particle size analyzer. The obtained RNCs were used for preparation of modified composite solid rocket propellants (CSRPs). Burning rate, thermal decomposition behavior, heat of combustion, sensitivity, and mechanical properties of CSRPs were determined. The results showed increases in the combustion energy and the burning rate of the modified propellants were achieved, and that RNCs can be considered to be promising multi‐function additives for composite solid rocket propellants. In addition, the mechanical properties and sensitivities of the modified propellants are within the desired range.     

Thermal‐crosslinked polyacrylonitrile fiber compacts

Polyacrylonitrile (PAN) textile fibers, in the form of fabrics or threads, were compacted in a heat‐pressure cycle and crosslinked by nitrile polymerization to form a thermoset composite article, whose mechanical properties were found to surpass those of commercially available polypropylene (PP) fiber counterparts. Additional advantages of the PAN compacts included their significant thermal stability (>300°C, i.e., twice that of PP) in addition to their flame retardancy, thereby rendering them as the structural material of choice for applications where heat protection and fire resistance are essential. Copyright © 2009 John Wiley & Sons, Ltd.     

A review on flammability of epoxy polymer,cellulosic and non‐cellulosic fiber reinforced epoxy composites

Natural fiber is well‐known reinforcement filler in polymer‐matrix composites. Composite components like organic polymers and natural fibers are natural fire conductors as the natural fiber consists of cellulose, hemicellulose, and lignin, and hence are as highly flammable as wood. Natural fiber reinforced composite materials are progressively being used in a variety of applications where their fire response is a hazardous consideration, for example, in the automotive (transportation) and building‐construction industries. As a result, an awareness of their performance or response during a fire and the use of conventional fire retardants are of great importance, as they are subject to thermal decomposition when exposed to intensive high heat or fire sources. In this review paper, fire flammability is the main concern for cellulosic and non‐cellulosic fiber‐reinforced polymer composites, especially epoxy composites. This paper reviews the literature on the recent developments in flammability studies concerning polymers, epoxy polymers, cellulosic‐fibers, and non‐cellulosic fiber‐reinforced epoxy bio‐composites. The prime objective of this review is to expand the reach of “fire retardants for polymer materials and composites” to the science community, including physicists, chemists, and engineers in order to broaden the range of their applications. Copyright © 2015 John Wiley & Sons, Ltd.     

Extraction and characterization of new cellulosic fibers from Indian mallow stem: An exploratory investigation

Natural fibers are one of the good alternative sources for replacing synthetic fiber and reinforcing polymer matrices because of their eco-friendly nature. This investigation deals with the extraction and characterization of new natural fiber from Indian mallow plant stem. The physico-chemical, thermal, and mechanical properties of Indian mallow fibers (IMFs) were reported and compared with other natural fibers for the first time. Cellulose (78.22%), wax (0.47%), density (1.33 g/cm³), and tensile strength (979.83 MPa) were recognized in IMFs. Fourier transform-infrared spectroscopy, X-ray diffraction, and thermo-gravimetric analysis confirmed that IMFs are rich in cellulose content and thermally stable with a crystallinity index of 72%.     

Nanoclay modified silica phenolic composites: mechanical properties and thermal response under simulated atmospheric re‐entry conditions

Ablative nanocomposites based on nanoclay‐dispersed addition curable propargylated phenolic novolac (ACPR) resin, reinforced with chopped silica fiber, were investigated for their thermal response behavior under simulated heat flux conditions corresponding to typical atmospheric re‐entry conditions. Organically modified nanoclay (Cloisite 30B) was incorporated to different extents (1–10%) in the ACPR resin matrix containing silica fiber to form the composite. The composites displayed optimum mechanical properties at around 3 wt% of nanoclay loading. The resultant composites were evaluated for their ablative characteristics as well as mechanical, thermal and thermo‐physical properties. The reinforcing effect of nanoclay was established and correlated to the composition. The mechanical properties of the composites and its pyrolysed product improved at moderate nanoclay incorporation. Plasma arc jet studies revealed that front wall temperature is lowered by 20°C and that at backwall by 10–13°C for the 3 wt% nanoclay‐incorporated composites due to impedance by nanoclay for the heat conduction. Nanoclay diminished the coefficient of thermal expansion by almost 50% and also reduced the flammability of the composites. The trend in mechanical properties was correlated to the microstructural morphology of the composites. The nanomodification conferred better strength to the pyrolysed composites. Copyright © 2014 John Wiley & Sons, Ltd.     

Intumescent flame retardation and silane crosslinking of PP/EPDM elastomer

This study deals with the silane crosslinking and intumescent flame retardation of polypropylene/ethylene‐propylene‐diene copolymer (PP/EPDM) elastomers. The effect of silane crosslinking on the flame retardancy of the PP/EPDM composites containing melamine phosphate (MP) and dipentaerythritol (DPER) was studied by limiting oxygen index, UL 94 and cone calorimetry tests. The chemical composition of the silane crosslinked and flame retarded PP/EPDM composites treated at different temperatures was studied by X‐ray photoelectron spectroscopy and real time Fourier transform infrared (FTIR) spectrometry. Thermal decomposition and crystallization behavior of the PP/EPDM composites were investigated using thermogravimetric analysis and differential scanning calorimetry, respectively. Moreover, the mechanical properties of the composites were also studied. It is found that the flame retardancy, mechanical properties, and thermal decomposition behavior of the composites are influenced by silane grafting and crosslinking. Copyright © 2008 John Wiley & Sons, Ltd.     

热场效应下聚酰亚胺纤维力学性质有限元分析

利用COMSOL Multiphysics 5.3软件构建了聚酰亚胺纤维三维有限元模型。 该模型实现了固体传热和表面对表面辐射传热产生的温度场中聚酰亚胺纤维固体力学的计算,重点分析了孔洞的大小、位置和热膨胀系数的差异对聚酰亚胺纤维力学性能的影响。 结果表明,聚酰亚胺(PI)纤维在两端固定约束的条件下,在固体传热和表面对表面辐射传热产生的温度场中呈现相似的应力变化趋势,即聚酰亚胺纤维出现孔洞,使纤维的力学性能降低,孔洞越大,应力分布越不均衡,越不利于纤维性质的稳定;温度越高,应力越大;但随着负轴向热膨胀系数的增加,应力逐渐减小。     

Study of the fire resistant behavior of unfilled and carbon nanofibers reinforced polybenzimidazole coating for structural applications

With increasing interest in epoxy‐based carbon fiber composites for structural applications, it is important to improve the fire resistant properties of these materials. The fire resistant performance of these materials can be improved either by using high performance epoxy resin for manufacturing carbon fiber composite or by protecting the previously used epoxy‐based composite with some fire resistant coating. In this context, work is carried out to evaluate the fire resistance performance of recently emerged high performance polybenzimidazole (PBI) when used as a coating material. Furthermore, the effect of carbon nanofibers (CNFs) on fire resistant properties of inherently flame retardant PBI coating was studied. Thermogravimetric analysis of carbon/epoxy composite, unfilled PBI and nano‐filled PBI shows that the carbon/epoxy composite maintained its thermal stability up to a temperature of 400°C and afterwards showed a large decrease in mass, while both unfilled PBI and nano‐filled PBI have shown thermal stability up to a temperature of 575°C corresponding to only 11% weight loss. Cone calorimeter test results show that unfilled PBI coating did not improve the fire retardant performance of carbon/epoxy composite. Conversely, nano‐filled PBI coating has shown a significant improvement in fire retardant performance of the carbon/epoxy composite in terms of increased ignition time, reduced average and peak heat release rate and reduced smoke and carbon monoxide emission. These results indicate that addition of carbon nanofibers to inherently flame retardant coating can significantly be helpful for improving the fire resistance performance of composite materials even with low coating thickness. Copyright © 2013 John Wiley & Sons, Ltd.     

Effects of polylactic acid and rPET minor components on phase evolution,tensile and thermal properties of polyethylene‐based composite fibers

High mechanical performance and partially biodegradable PE‐composite fibers modified with polylactic acid (PLA) and recycled polyethylene terephthalate (rPET) minor components were prepared using melt extrusion and hot drawing process. Rheological properties, morphology, tensile, and thermal properties were investigated. All blends exhibited shear thinning behavior except for starting PLA and rPET. PLA and rPET dispersed phases appeared as droplets in as‐extruded strand, and PLA droplets were mostly larger than those of rPET. The fibrillation of both PLA and rPET domains was achieved after further hot drawing as the fiber. The morphology and tensile properties of the fibers mainly depended on the types and contents of dispersed phases including draw ratios. The ultimate strength of the polymer fibers at draw ratio of 20 was more than 600 times higher than that of the as‐spun sample of the same composition. Remarkable improvement in secant modulus and ultimate strength was found for PE‐30PLA, but the drawing process of this composition encountered some difficulties and rough surface of the fiber was observed. The stiffness and tensile stress for PE‐10PLA‐10rPET fiber were clearly improved when compared with PE and PE‐10PLA. A decrease in thermal stability of PE/PLA composites was observed with increasing PLA content whereas additional presence of rPET significantly increased the stability of the composites both in nitrogen and in air. PE/PLA/rPET fiber possessing high stiffness with good thermal stability prepared in this work has high potential for being utilized as structural parts for load‐bearing applications.     

Properties of ethylene propylene diene rubber/white and black filler composites cured by gamma radiation in presence of sorbic acid

The effect of incorporating sorbic acid (SA), an echo-friendly curing agent, and silica or carbon black (CB) filler, as well as gamma irradiation on the physico-chemical, mechanical and thermal properties of ethylene propylene diene monomer rubber (EPDM) was investigated. The results indicated that the developed composites revealed improvement in the studied parameters over the untreated samples. Filler incorporation into rubber matrix has been proven a key factor in enhancing the swelling resistance, tensile strength and thermal properties of the fabricated composites. The improvement in tensile strength and modulus was attributed to better interfacial bonding via SA. Alternatively, a comparison was established between the performance of the white and black fillers. The utmost mechanical performance was reported for the incorporated ratios 10 phr SA and 40 phr white filler into a 50 kGy irradiated composite. Meanwhile, the incorporation of CB yielded better thermally stable composites than those filled with silica at similar conditions.     

Effect of ZnO nanoparticles on kinetics of thermal degradation and final properties of ethylene–propylene–diene rubber systems

The morphology, thermal degradation behavior in addition to static and dynamic mechanical properties of various ethylene?Cpropylene?Cdiene (EPDM) rubber compounds containing nano-zinc oxide (NZnO) were investigated compared to those of EPDM with ordinary-sized ZnO (OSZnO). The field-emission scanning electron microscopy studies showed that unlike the conventional system, the formation of large size ZnO agglomerates was discouraged for NZnO filled systems. Thermogravimetric analysis (TG) revealed that the thermal degradation of EPDM system was delayed upon the inclusion of NZnO instead of OSZnO in the compound. The kinetic analysis of TG data based on Friedman and Kissinger methods showed that the nanocomposite samples exhibited higher activation energy (E _a ) and lower order of reaction (n) over the conventional system, suggesting the enhancement of thermal stability upon decreasing ZnO particle size. The results obtained from dynamic mechanical analysis and static mechanical characterizations in terms of hardness, resilience, and abrasion tests interestingly indicated that NZnO not merely could act as a thermal insulator, but also could perform as a nano-filler to improve the final performance of EPDM elastomers.     

Development and characterisation of vinyloxyaminosilane grafted ethylene-propylene-diene terpolymer (EPDM-g-VOS) for engineering applications

A novel and new copolymer of vinyloxyaminosilane grafted ethylene-propylene-diene terpolymer (EPDM-g-VOS) has been synthesised in toluene using dicumyl peroxide as initiator. The grafting efficiency of vinyloxyaminosilane (VOS) onto ethylene-propylene-diene terpolymer (EPDM) has been studied as a function of EPDM content, reaction time, reaction temperature and initiator concentration. Using the optimum grafting efficiency conditions, EPDM-g-VOS has also been developed in a Haake Rheocord-90, torque rheometer. The grafting of vinyloxyaminosilane onto ethylene-propylene-diene terpolymer (EPDM-g-VOS) has been confirmed by Fourier-transform infrared spectroscopy. The mechanical, thermal, and electrical, properties of hot water cured EPDM-g-VOS and peroxide cured EPDM are compared. The mechanical properties of EPDM-g-VOS are decreased due to the flexibility imparted by VOS. However thermal and dielectric properties are increased due to the introduction of VOS onto EPDM as well as the formation of thermally stable three dimensional network through Si-O-Si- linkage.     

Mechanical, thermal, and fire retardant properties of poly(ethylene terephthalate) fiber containing zinc phosphinate and organo-modified clay

The effect of zinc bisdiethylphosphinate (ZnPi) and organoclay on mechanical, thermal, and flame retardant properties of poly(ethylene terephthalate) (PET) fiber was investigated. ZnPi was preferred due to its fusible character at spinning temperature and organoclay was used for synergistic interaction. The mechanical, thermal, and flame retardant properties of fibers were examined by tensile testing, thermogravimetric analysis (TG), and micro combustion calorimeter (MCC). The tensile strength of the PET fiber reduced with the addition of both ZnPi and organoclay. The TG results showed that the inclusion of ZnPi increased the char residue. The MCC results showed that the addition of organoclay increased the barrier effect of formed char which depends on char amount, thickness, and integrity and reduces the maximum heat evolved during the test. This result was also important in terms of showing that the organoclay was effective in thermally thin samples.