Search Results (19)

Polyurethane (PUR)-based artificial leathers are often used as interior materials in public area, making flame retardants (FRs) necessary. The mode of action of different FRs varies depending on the chemical class and the structure of the supplied material. Usually, FRs are designed for bulk materials like foams, e.g., for upholstery, the main application of PUR. However, in thin materials, FRs act differently, thus leaving the PUR without sufficient flame resistance. In this study, PUR films and artificial leathers were equipped with twelve commercially available, halogen-free FRs in various concentrations and combinations. Fire resistance was tested with LOI measurements, cone calorimetry, horizontal burning behavior, and thermogravimetric analyses. An organophosphorus FR proved to be the most suited for flame-resistant artificial leather. The LOI was increased from 20 to 24.2%, the peak heat release rate was reduced by about 30%, and the sample was self-extinguishing in horizontal burning behavior. Phosphinates and aluminum trihydroxide were the least efficient FRs. Combinations of bentonite with phosphorus-based FRs showed synergistic effects in reducing the probability of igniting the material. The results demonstrate that sufficient flame retardancy for PUR-based thin materials can be achieved with commercially available halogen-free FRs, paving the way for more sustainable and greener materials by substituting ecologically harmful and health-damaging FRs. Full article

Focusing on solving the adverse laser-inducing damage problem, high-power laser-resistant strategies have attracted more attention. In order to improve the laser-resistant property, a novel dynamic porous structure generation idea for laser irradiation was presented in this study, both of high-reflection and reaction endothermic effects. A detailed investigation on phase structure change, optical properties variation, micro-structure evolution, and substrate temperature development during laser irradiation was performed. The initial reflectivity of two coatings at 1064 nm was high, around 80–90%. During laser irradiation, the reflectivity grew continuously, reaching a maximum of 93%. During laser irradiation, a skeleton porous structure formed, promoted by the endothermic reaction of aluminum tri-hydroxide, whose structure contributes to the heat insulation from surface to interior. Thus, the prepared coating showed excellent anti-laser ablation performance, being dependent on its thermal insulation by the reaction-generated porous structure; high reflectivity by surface; and heat dissipation by endothermic reaction. Under 2000 W/cm², 10 s laser irradiation (spot area is 10 mm × 10 mm), the back-surface temperature is just 159 °C, which is far away from the melting point of aluminum substrate. The coatings and strategy mentioned in this study have a great potential to be applied in the anti-laser field. Full article

This research studies natural rubber (NR) composite blends prepared with recycled polyethylene (PE), polyurethane waste (PU), silica (SiO₂), and aluminum trihydroxide (ATH) under the proper mixing conditions using an internal mixer and a two-roll mill. The mechanical, impact, dynamic mechanical, and thermal properties, together with flammability, were investigated. NR/PU composites filled with a specific SiO₂/ATH concentration resulted in excellent flame-retardant properties without using PE. Adding PE causes poor flammability, while using PU and SiO₂ prevents flame extensibility of the composites. In addition, SiO₂ and ATH synergistically improved both mechanical and dynamical mechanical properties. This is attributed to the reinforcement of SiO₂ particles inside the matrix, whereas the ATH releases water as a flame retardant. The V-0 composites tested with UL-94 showed acceptable heat resistance, strength, and durability, making them suitable for interior and exterior applications in buildings without the lightweight requirement. Full article

Air-polishing powders are used to remove stains from the enamel and various restorative materials, but their effect on the discoloration of CAD/CAM blocks remains scarce. Therefore, this study investigated the effect of various air-polishing powders on the color changes in different CAD/CAM blocks to predict the esthetic outcomes. Specimens were prepared from CAD/CAM blocks (Vita Mark II, Paradigm MZ100, Lava Ultimate, Cerasmart, Vita Enamic) and divided into five groups (n = 10) according to the air-polishing powder: sodium bicarbonate; aluminum trihydroxide; calcium carbonate; glycine; and erythritol. Color parameters were measured with a spectrophotometer before and after air-polishing. The color difference was calculated with the ΔE₀₀ formula. Data were statistically evaluated with one-way ANOVA, Tukey, and two-way ANOVA tests (α = 0.05). The CAD/CAM block type and the air-polishing powder type significantly influenced the ΔE₀₀ value, whereas their interactions did not affect it significantly. Calcium carbonate and aluminum trihydroxide significantly increased the ΔE₀₀ values of Lava Ultimate and Cerasmart. Although none of the groups exceeded the acceptability threshold (ΔE₀₀ = 1.8), most exceeded the perceptibility threshold (ΔE₀₀ = 0.8). Consequently, dentists should avoid air-polishing or should repolish with care, depending on restorative material knowledge, to maintain color stability when uncertain about the material encountered clinically. Full article

The fire performance of epoxy and carbon-fiber-reinforced polymer (CFRP) composites with and without fire retardants (FR) (i.e., ammonium polyphosphate (APP), aluminum trihydroxide (ATH), melamine (MEL), expandable graphite (EG)) was investigated. A design of experiment (DoE) approach was applied to study the single- and multifactorial effects of FR. The fire performance of epoxy and CFRP was evaluated by limiting the oxygen index (LOI) and heat release, which were obtained by limiting the oxygen index test and cone calorimetry. It was found that mixtures of 70 wt.-% epoxy, 24.6 wt.-% of APP, and 5.4 wt.-% MEL resulted in the highest LOI level of 45 within tested groups for epoxy resin and also for CFRP specimens (LOI level of 39). This mixture also resulted in the lowest average heat release rate (HRR_180s) of 104 kW·m⁻² and a spec. total heat release (THR_600s) of 1.14 MJ·m⁻²·g⁻¹, indicating the importance of balancing spumific and charring agents in intumescent systems and synergy thereof. Full article

Glass fiber reinforced plastic (GFRP) composites have great potential to replace metal components in vehicles by maintaining their mechanical properties and improving fire resistance. Ease of form, anti-corrosion, lightweight, fast production cycle, durability and high strength-to-weight ratio are the advantages of GFRP compared to conventional materials. The transition to the use of plastic materials can be performed by increasing their mechanical, thermal and fire resistance properties. This research aims to improve the fire resistance of GFRP composite and maintain its strength by a combination of pumice-based active nano filler and commercial active filler. The nano active filler of pumice particle (nAFPP) was obtained by the sol–gel method. Aluminum trihydroxide (ATH), sodium silicate (SS) and boric acid (BA) were commercial active fillers that were used in this study. The GFRP composite was prepared by a combination of woven roving (WR) and chopped strand mat (CSM) glass fibers with an unsaturated polyester matrix. The composite specimens were produced using a press mold method for controlling the thickness of specimens. Composites were tested with a burning test apparatus, flexural bending machine and Izod impact tester. Composites were also analyzed by SEM, TGA, DSC, FT-IR spectroscopy and macro photographs. The addition of nAFPP and reducing the amount of ATH increased ignition time significantly and decreased the burning rate of specimens. The higher content of nAFPP significantly increased the flexural and impact strength. TGA analysis shows that higher ATH content had a good contribution to reducing specimen weight loss. It is also strengthened by the lower exothermic of the specimen with higher ATH content. The use of SS and BA inhibited combustion by forming charcoal or protective film; however, excessive use of them produced porosity and lowered mechanical properties. Full article

Fire resistance is a major issue concerning composite materials for safe operation in many industrial sectors. The design process needs to meet safety requirements for buildings and vehicles, where the use of composites has increased. There are several solutions to increasing the flame resistance of polymeric materials, based on either chemical modification or physical additions to the material’s composition. Generally, the used flame retardants affect mechanical properties either in a positive or negative way. The presented research shows the influence of the mixed-mode behavior of epoxy resin. Fracture toughness tests on epoxy resin samples were carried out, to investigate the changes resulting from different inorganic filler contents of aluminum trihydroxide (ATH). Three-point bending and asymmetric four-point bending tests, with different loading modes, were performed, to check the fracture behavior in a complex state of loading. The results showed that the fracture toughness of mode I and mode II was reduced by over 50%, compared to neat resin. The experimental outcomes were compared with theoretical predictions, demonstrating that the crack initiation angle for higher values of KI/KII factor had a reasonable correlation with the MTS prediction. On the other hand, for small values of the factor K_I/K_II, the results of the crack initiation angle had significant divergences. Additionally, based on scanning electron microscopy images, the fracturing of the samples was presented. Full article

The desilication of sodium aluminate solutions prior to precipitation of aluminum tri-hydroxides is an essential step in the production of high purity alumina for aluminum production. This study evaluates the desilication of sodium aluminate solutions derived from the leaching of calcium-aluminate slags with sodium carbonate, using CaO, Ca(OH)₂, and MgO fine particles. The influence of the amount of CaO used, temperature, and comparisons with Ca(OH)₂ and MgO were explored. Laboratory scale test work showed that the optimal conditions for this process were using 6 g/L of CaO at 90 °C for 90 min. This resulted in 92% of the Si being removed with as little as 7% co-precipitation of Al. The other desilicating agents, namely Ca(OH)₂ and MgO, also proved effective in removing Si but at slower rates and higher amounts of Al co-precipitated. The characteristics of solid residue obtained after the process indicated that the desilication is via the formation of hydrogarnet, Grossular, and hydrotalcite dominant phases for CaO, Ca(OH)₂ and MgO agents, respectively. Full article

A magnesium potassium phosphate hydrate-based flame-retardant coating (MKPC) is formulated by dead-burnt magnesium oxide (magnesia) and potassium dihydrogen phosphate (KH₂PO₄), behaving as a matrix. Constituents of the MKPC include wollastonite, vermiculite, aluminum fluoride, aluminum trihydroxide, and calcium carbonate. Some of the ingredients inter-react to produce mullite whiskers at high temperatures, despite an acid-base hydration induced reaction between magnesia and KH₂PO₄. The MKPC’s thermal, corrosion-resistant, mechanical, and flame-resistant properties were analyzed using scanning electron microscopy, electrochemical corrosion testing, compression testing, thermogravimetric analysis, and freeze/thaw tests. The results show that with the molar ratio = 4 of magnesia to KH₂PO₄, MKPC demonstrates lower thermal conductivity (0.19 W/m K), along with better corrosion resistance, stronger compressive strength (10.5 MPa), and higher bonding strength (6.62 kgf/cm²) to the steel substrate. Furthermore, acceptable additives to the formulation could enhance its flame-retardancy and increase its mechanical strength as well. Mullite whisker formed from the interaction of wollastonite, aluminum trihydroxide, and aluminum fluoride acts as an outer ceramic shield that enhances mechanical strength and compactness. In addition, Mg-containing minerals with calcium carbonate treated at high temperatures, transform into magnesium calcium carbonate after releasing CO₂. At the optimum composition of MKPC (magnesia/KH₂PO₄ molar ratio = 4; wollastonite:vermiculite = 20:10 wt.%; aluminum trihydroxide = 10 wt.%; and calcium carbonate = 5 wt.%), coated on a steel substrate, the flame-resistance limit results exhibit below 200 °C on the back surface of the steel substrate after one hour of flaming (ca. 1000 °C) on the other surface, and the flame-resistance rating results demonstrate only 420 °C on the back surface of the steel substrate after three hours of flaming (>1000 °C) on the other surface. Both requirements for the flame-resistance limit and three-hour flame-resistance rating are met with the optimum compositions, indicating that MKPC plays an effective role in establishing flame-retardancy. Full article

This study investigates applying the principles of the long-discontinued Pedersen process as a possible route for producing metallurgical grade alumina from low-grade and secondary feed materials. The investigation focused on the hydrometallurgical steps in the process, namely leaching, desilication, and precipitation, and adapting it to valorize bauxite residue. The test material used was a calcium–aluminate slag made by the smelting-reduction of a mixture of bauxite residue (dewatered red mud) and a calcium-rich bauxite beneficiation by-product. Samples of the slag were leached in a 1 L jacketed glass reactor with Na₂CO₃ solution, varying Na₂CO₃ concentration and leaching time. Additionally, different approaches to leaching involving mechanical treatment of the leached slag and re-leaching using either fresh or recycled solution were also explored. The desilication step was carried out by treating the leachate solution with powdered CaO, varying the amounts of CaO used. Finally, the desilicated leach solution was sparged with a CO₂ gas mixture, after which the precipitate was allowed to age in the solution. The carbonation and aging temperatures and times were varied. As much as 67% of the Al was leached from the slag. The desilication process successfully removed 88% of the Si. The precipitation process produced a product composed mostly of bayerite [Al(OH)₃], but some tests had considerable amounts of the unwanted phase dawsonite [NaAlCO₃(OH)₂]. The results indicated that the highest Al recovery was obtained using low concentrations of Na₂CO₃ solutions, and aluminum tri hydroxide is formed from these solutions at low temperatures at a fast rate compared to higher solution concentrations and temperatures. Full article

Sustainable coating solutions that function as a fire retardant for wood are still a challenging topic for the academic and industrial sectors. In this study, composite coatings of casein protein mixed with mica and aluminum trihydroxide (ATH) were tested as fire retardants for wood and plywood; coating degradation and fire retardancy performance were assessed with a cone calorimeter, and a thermogravimeter was used for the thermal stability measurement. The results indicated that casein–mica composites were beneficial as coatings. The heat release rate (HRR) and the total heat released (THR) of the sample coated with casein–mica composite were reduced by 55% and 37%, respectively; the time to ignition was increased by 27% compared to the untreated sample. However, the TTI of the sample coated with the casein–mica–ATH composite was increased by 156%; the PHR and THR were reduced by 31% and 28%, respectively. This is attributed to the yielded insulating surface layer, active catalytic sites, and the crosslink from mica and endothermic decomposition of ATH and casein producing different fragments which create multiple modes of action, leading to significant roles in suppressing fire spread. The multiple modes of action involved in the prepared composites are presented in detail. Coating wear resistance was investigated using a Taber Abrader, and adhesion interaction between wood and a coated composite were investigated by applying a pull-off test. While the addition of the three filler types to casein caused a decrease in the pull-off adhesion strength by up to 38%, their abrasion resistance was greatly increased by as much as 80%. Full article

In this work, we study three aluminum oxides (alpha, gamma, boehmite) and various oxidized metallic aluminum powders to observe their dehydration and decomposition behavior using in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) and scanning electron microscopy (SEM). We find that a temperature increase to the aluminum oxides (aluminas) reduces physically adsorbed water molecules to reveal the presence of hydroxyl groups. All three aluminas contained bridged hydroxyls located at 3670 cm⁻¹; we found additional surface hydroxyls, which varied based on the oxidation state of the aluminum atom. Oxidized metallic aluminum powders that were aged resulted in similar behavior; however, the results differed depending on the method of aging. We find that naturally aged aluminum (NA-Al) powders with heavy oxidation in the form of the tri-hydroxide decomposed and did not reveal any detectable surface hydroxyl peaks. When aged using artificial methods (AA-Al), we find both surface hydroxyls, including bridged hydroxyls at 3670, 3700, and 3730 cm⁻¹, and a remaining boehmite-like surface. These results show that metallic aluminum powders can be tailored for specific applications, regardless of age. It also elucidates different ways to pre-process the powders to control the surface oxide layer, corroborated by comparison with the models oxides studied herein. Full article

In this work, sodium aluminate alkaline solution was used to capture CO₂ in a continuous bubble column scrubber and aluminum tri-hydrate (ATH) precipitates were produced. As the sodium carbonate could be recycled after the filtrated solution was crystallized by evaporation, a novel CO₂ capture process was developed successfully. There were five experimental operation variables, including solution flow rate (A), concentration of the solution (B), gas flow rate (C), CO₂ gas concentration (D), and liquid temperature (E), with four levels to each variable. The influence of each variable on absorption efficiency (EF), absorption rate (R_A), absorption factor (φ), mass transfer coefficient (K_Ga), and precipitation rate (R_P) in a steady state was explored in this study. The Taguchi experimental design was adopted, and 16 experiments were performed; as the optimum operating conditions found in Taguchi analysis required further verification, there were a total of 21 experiments in the end. According to S/N analysis, the overall order of importance was D > A = B > C > E, meaning D (CO₂ concentration) was most important and E (liquid temperature) was least important. In addition, the result also showed that the Rp was 1.25–2.0 times higher than the RA. The obtained powder was mainly ATH according to XRD analysis, with the crystal size ranging between 8.14 and 27.97 nm. However, the BET analysis showed its particle size range being 17.6–283.7 nm, indicating agglomeration for primary particles. The SEM analysis showed that there were flower-like, irregular, urchin-like, elongated, and amorphous particles. The solutions from five groups of optimum conditions were used to recycle the sodium carbonate experiments. After evaporation and crystallization of the filtrated solutions, the energy loading was found to be 1.70–2.56 GJ/t-solvent, illustrating the superiorities of low energy consumption. The precipitated powders were verified to be sodium carbonate by FTIR, which is a valuable constituent. Full article

This study proposes an innovative solution to flame-retard a sandwich composite made of unsaturated polyester resin, glass fibre skins and polyester nonwoven core material. The strategy uses the core material as flame-retardant carrier, while the resin is also flame-retarded with aluminum trihydroxide (ATH). A screening of the fire-retardant performances of the core materials, covered with different types of phosphorous flame-retardant additives (phosphate, phosphinate, phosphonate), was performed using cone calorimetry. The best candidate was selected and evaluated in the sandwich panel. Great performances were obtained with ammonium polyphosphate (AP422) at 262 g/m². The core material, when tested alone, did not ignite, and when used in the laminate, improved the fire behaviour by decreasing the peak of heat release rate (pHRR) and the total heat release (THR): the second peak in HRR observed for the references (full glass monolith and sandwich with the untreated core) was suppressed in this case. This improvement is attributed to the interaction occurring between the two FR additives, which leads to the formation of aluminophosphates, as shown using Electron Probe Micro-Analysis (EPMA), X-ray Diffraction (XRD) and solid-state ³¹P Nuclear Magnetic Resonance (NMR). The influence of the FR add-on on the core, as well as the ATH loading in the matrix, was studied separately to optimize the material performances in terms of smoke and heat release. The best compromise was obtained using AP422 at 182 g/m² and 160 phr of ATH. Full article

Aluminum hydroxide is an essential material for the industrial production of ceramics (especially insulators and refractories), desiccants, absorbents, flame retardants, filers for plastics and rubbers, catalysts, and various construction materials. The calcination process of Al(OH)₃ first induces dehydration and, finally, results in α-Al₂O₃ formation. Nevertheless, this process contains various intermediary steps and has been proven to be complicated due to the development of numerous transitional alumina. Each step of the investigation is vital for the entire process because the final properties of materials based on aluminum trihydroxide are determined by their phase composition, morphology, porosity, etc. In this paper, five dried, milled, and size-classified aluminum hydroxide specimens were thermally treated at 260, 300, and 400 °C; then, they were studied in order to identify the effects of temperature on their properties, such as particle morphology, specific surface area, pore size, and pore distribution. The major oxide compounds identified in all samples were characteristic of bauxite—namely, Al₂O₃ * 3H₂O, SiO₂, Fe₂O₃, Na₂O, and CaO. Particles with smaller sizes (<10 µm = 76.28%) presented the highest humidity content (~5 wt.%), while all samples registered a mass loss of ~25 wt.% on ignition at 400 °C. The identified particles had the shapes of hexagonal or quasi-hexagonal platelets and resulted in large spherulitic concretions. The obtained results suggest that ceramic powders calcined at 400 °C should be used for applications as adsorbents or catalysts due to their high specific area of about 200–240 m²/g and their small pore width (3–3.5 nm). Full article