Synergistic effects of zinc borate and aluminium trihydroxide on flammability behaviour of aerospace epoxy system

The flame retardancy of mono-component epoxy resin (RTM6), widely used for aerospace composites, treated with zinc borate (ZB), aluminium trihydroxide (ATH) and their mixtures at different concentrations have been investigated by morphological and thermal characterization. Cone calorimeter data reveal that combustion behaviour, heat release rate peak (PHRR) and heat release rate average (HRR Average) of RTM6 resin decrease substantially when synergistic effects of zinc borate and aluminium trihydroxide intervene. Thermogravimetric (TGA) results and analysis of the residue show that addition higher than 20% w/w of ZB, ATH, and their mixture greatly promotes RTM6 char formation acting as a barrier layer for the fire development. Depending upon the different used flame additives, SEM micrographs indicate that the morphology of residual char could vary from a compact amalgam-like structure, for the RTM6+ZB system, to a granular structure, characterized by very small particles of degraded resin and additive for the ATH.