Ignition performance of new and used motor vehicle upholstery fabrics

This paper examines the standards for fire safety in transport systems and in particular the test method for the flammability of materials within passenger compartments of motor vehicles. The paper compares data from ignition tests conducted in the cone calorimeter and the FIST apparatus with tests conducted using the FMVSS 302 horizontal flame spread apparatus. Ten materials were selected as representative of those used as seat coverings of private and commercial passenger vehicles. The time to ignition of new and used materials subject to exposure heat fluxes between 20 kW/m² and 40 kW/m² was measured. The results from the ignition tests were analysed using thermally thick and thermally thin theoretical models. The critical heat flux for sustained piloted ignition was determined from the time to ignition data using the thermally thin approach. Derived ignition temperatures from both the thermally thick and thermally thin methods were compared with measurements using a thermocouple attached to the back surface of materials in selected tests. The flame spread rates in the FMVSS 302 apparatus were determined and a comparison was made between the performance of the materials in the flame spread apparatus, the cone calorimeter and the FIST. The results suggests that a critical heat flux criterion could be used to provide an equivalent pass/fail performance requirement to that specified by the horizontal flame spread test although further testing is needed to support this. Copyright © 2004 John Wiley & Sons, Ltd.     

A theoretical basis for flammability properties

Theoretical formulations are presented for the fire growth processes under external radiant heating. They included ignition, burning and energy release rate, and flame spread. The behaviour of these processes with external heating is described along with the critical conditions that limit them. These include the critical heat fluxes for ignition, flame spread and burning rate. It is shown how these processes and their critical conditions depend on a limited number of properties measurable by a number of standard test methods. The properties include heat of combustion, the heat of gasification, ignition temperature and the thermal properties of the material. Alternatively, the properties could be related to parameters easily found from data; namely: (1) the critical heat flux (CHF) for ignition; (2) the slope of the energy release rate with externally imposed flux, defined as heat release parameter (HRP); and (3) the ignition parameter, defined as thermal response parameter (TRP). It is further shown that the flame heat flux differences between small laminar flame ignition sources and larger turbulent flames can affect flame spread due to heat flux and ignition length factors. Finally, it is found that the critical energy release rates theoretically needed for ignition, sustained burning, and turbulent upward flame spread are roughly 13, 52, and 100 kW/m², respectively, and independent of material properties. Copyright © 2005 John Wiley & Sons, Ltd.     

Ignition and combustion of low‐density polyimide foam

The ignition, flaming and smoldering combustion of low‐density polyimide foam have been studied using a cone calorimeter. Low‐density polyimide foam exhibits a high ignition resistance. The minimum heat flux for the ignition of flaming combustion ranges from 48 to 54 kW/m². This minimum heat flux also indicates the heat flux for transition from smoldering to flaming combustion. The flaming combustion results show that the heat release rate of low‐density polyimide foam is very low even at a high incident heat flux of 75 kW/m². The smoldering combustion results show that the smoldering of low‐density polyimide foam becomes significant when the incident heat flux is greater than 30 kW/m². The smoldering combustion of low‐density polyimide foam cannot be self‐sustaining when the external heat source is removed. Copyright © 2003 John Wiley & Sons, Ltd.     

Comparison of cone and OSU calorimetric techniques to assess the flammability behaviour of fabrics used for aircraft interiors

Two test methods for measuring the heat release rate, HRR have been compared on fabric composites used for aircraft interior materials as side‐wall panels. These methods are based on the principles of direct measurement of the convective and radiant heat by thermopiles using an Ohio State University (OSU) calorimeter, and oxygen consumption using a cone calorimeter. It has been observed when tested by standard procedures, cone results at 35 kW/m² incident heat flux do not correlate with OSU results at the same heat flux. This is because in the cone calorimeter, the sample is mounted horizontally whereas the OSU calorimetric method requires vertical sampling with exposure to a vertical radiant panel. A further difference between the two techniques is the ignition source—in the cone it is spark ignition, whereas in the OSU it is flame ignition; hence, samples in the OSU calorimeter ignite more easily compared to those in the cone under the same incident heat fluxes. However, in this paper we demonstrate that cone calorimetric exposure at 50 kW/m² heat flux gives similar peak heat release results as the 35 kW/m² heat flux of OSU calorimeter, but significantly different average and total heat release values over a 2 min period. The performance differences associated with these two techniques are also discussed. Moreover, the effects of structure, i.e. type of fibres used in warp/weft direction and design of fabric are also analysed with respect to heat release behaviour and their correlation discussed. Copyright © 2005 John Wiley & Sons, Ltd.     

Experimental and analytical protocol for ignitabiilty of common materials

In this study, a protocol was developed to increae accuracy, generality and efficiency when determining piloted ignition properties. A new procedure for calibrating the radiative and convective heat flux protiels on exposed speciments, such as Douglas-fir plywood, has been implemented for the lateral ignition and flame spread test (LIFT) apparatus. The boundary conditions needed for heat transfer anylysis are made unambiguous by including a simple, direct measure f surface emissivity. A new aluminum foil shutter improves accuracy for measuring ignition time. A recently developed theroy of ignitanility provides a formula to account for the transition form thick to thin thermal behaior, allowing specimens of finite thicknesses and a fuln range of test irradiances.     

The effects of geometry and ignition mode on ignition times obtained using a cone calorimeter and ISO ignitability apparatus

Three timber-based materials were investigated by subjecting them to a constant uniform heat flux in the range 20–70 kW m^?2 using a Cone Calorimeter and the ISO Ignitability Apparatus. The specimens were examined in the vertical and horizontal orientations in the Cone Calorimeter using gas flame pilot, spark pilot and spontaneous methods of ignition. They were also studied using the ISO Ignitability Apparatus in the normal and inverted horizontal orientations using gas flame pilot and spontaneous methods of ignition. The results obtained are compared by specimen, orientation and mode of ignition.     

An examination of piloted ignition characteristics of cellulosic materials using the ISO ignitability test

The ISO Ignitability Test apparatus is used to determine the times to ignition for cellulosic materials under an incident radiative flux within the range 1--5 kW/m². A linear relationship is determined between time to ignition and incident flux, and a means of using these results to classify building materials is proposed, based upon an empirical flux-time product.     

Application of cone calorimeter for the assessment of class of flame retardants for polypropylene

The study presented addresses the fire behaviour of polypropylene compounded with six classes of flame retardants. The application of cone calorimetry for the assessment of the thermal characteristics of the tested materials and their comparison with thermogravimetry are the central point of this research. This study only presents data for 25 kW/m² of incident heat flux exposure and includes five tests for polypropylene with no additives and five tests for polypropylene with flame retardants based on triglycidylisocyanurate and lignin. The data collected include the rate of heat release, mass loss rate, char yield, time to ignition and time of total combustion. Results represent meaningful comparison between the behaviour of the materials under simulated fire conditions, using the cone calorimeter, and in the slow dynamic environment utilized in thermogravimetric analysis. © 1998 John Wiley & Sons Ltd.     

Application of narrow‐spectrum illumination and image processing to measure surface char formation in lateral ignition and flame spread tests

The Lateral Ignition and Flame Spread Test (LIFT) is used to characterize fire ignition and flame spread on solid materials. This test requires the operator to visually monitor the flame spread over a combustible material and manually record the position of the flame during an experiment. Visual inspection limits the quantity of data obtained from a test and introduces uncertainty in the measurement. In this study, we use narrow‐spectrum light with a peak wavelength of 450 nm and a digital camera with frequency‐matched optical filters to capture images of surface charring, which underlies the flaming combustion, in a LIFT apparatus. The imaging technique reduced unwanted energy emissions from the flame in the visible light spectrum, allowing the test operator to directly view the charring of the material, which is otherwise hidden behind the flames. We describe data processing routines to analyze the sequences of high‐resolution images. The method improves temporal and spatial resolution of the surface charring compared with visual observations.     

Flammability characteristics at applied heat flux levels up to 200 kW/m2

This paper documents the first of the two interrelated studies that were conducted to more fundamentally understand the scalability of flame heat flux, the motivation being that it has been reported that flame heat flux back to the burning surface in bench‐scale experiments is not the same as for large‐scale fires. The key aspect was the use of real scale applied heat flux up to 200kW/m² which is well beyond that typically considered in contemporary testing. The main conclusions are that decomposition kinetics needs to be included in the study of ignition and the energy balance for steady burning is too simplistic to represent the physics occurring. An unexpected non‐linear trend is observed in the typical plotting methods currently used in fire protection engineering for ignition and mass loss flux data for several materials tested and this non‐linearity is a true material response. Using measured temperature profiles in the condensed phase shows that viewing ignition as an inert material process is inaccurate at predicting the surface temperature at higher heat fluxes. The steady burning temperature profiles appear to be invariant with applied heat flux. This possible inaccuracy was investigated by obtaining the heat of gasification via the ‘typical technique’ using the mass loss flux data and comparing it to the commonly considered ‘fundamental’ value obtained from differential scanning calorimetry measurements. This comparison suggests that the ‘typical technique’ energy balance is too simplified to represent the physics occurring for any range of applied heat flux. Observed bubbling and melting phenomena provide a possible direction of study. Copyright © 2007 John Wiley & Sons, Ltd.     

Flammability testing of pure and flame retardant-treated cotton fabrics

A Controlled-atomosphere cone calorimeter was used to investigate the burning of pure and flame retardant-treated cotton fabrics. The condensed-phase flame retardants used were Morguard (containing ammonium dihydrogen phosphate and diammonium hydrogen phoisphate) and Nochar (containing ammonium sulfate and a sodium salt). The fabrics were tested at 25 kW m^?2 incident heat flux in environments containing 15–30% oxygen. The flame retardants increased the time to ignition, residue yield, and CO and CO₂ yields. The flame retardants decreased the peak and average mass loss rates, the peak and average heat release rates, the effective heat of combustion at peak heat release rate, and the propensity to flashover. The effect of oxygen concentration on the burning of pure and flame retardant-treated cotton fabrics has also been investigated. The flame retardants had better performance when the treated fabrics burned in the lower oxyge concentrations. The result of this study indicate that the controlled-atmosphere cone calorimeter is a good tool for studying the effect of flame retardant and oxygen concentration on the burning of materials.     

Correlations between pyrolysis combustion flow calorimetry and conventional flammability tests with halogen‐free flame retardant polyolefin compounds

Seven halogen‐free flame retardant (FR) compounds were evaluated using pyrolysis combustion flow calorimetry (PCFC) and cone calorimetry. Performance of wires coated with the compounds was evaluated using industry standard flame tests. The results suggest that time to peak heat release rate (PHRR) and total heat released (THR) in cone calorimetry (and THR and temperature at PHRR in PCFC) be given more attention in FR compound evaluation. Results were analyzed using flame spread theory. As predicted, the lateral flame spread velocity was independent of PHRR and heat release capacity. However, no angular dependence of flame spread velocity was observed. Thus, the thermal theory of ignition and flame spread, which assumes that ignition at the flame front occurs at a particular flame and ignition temperature, provides little insight into the performance of the compounds. However, results are consistent with a heat release rate greater than about 66kW/m² during flame propagation for sustained ignition of insulated wires containing mineral fillers, in agreement with a critical heat release rate criterion for burning. Mineral fillers can reduce heat release rate below the threshold value by lowering the flaming combustion efficiency and fuel content. A rapid screening procedure using PCFC is suggested by logistic regression of the binary (burn/no‐burn) results. Copyright © 2008 John Wiley & Sons, Ltd.     

An investigation into the effects of gravity level on rate of heat release and time to ignition

Two experiments were performed on board an aircraft flying repeated parabolic trajectories to generate free-fal conditions. The first experiment investigates the way in which rate of heat release (RHR) varies with gravity for a candle flame under an imposed low-speed flow. In line with previous studies of flame spread rate it has been shown that rate of heat release drops significantly in imcrogravity. The heat loss due to radiation decreases by a larger proportion than that due to non-radiative processes indicating a lower flame temperature. The RHR from a microgravity flame is flow rate dependent, increasing for increased flow rate at air speeds under 0.03 ms^?1. For the geometry used in this experiment hypergravity caused only a small increase in RHR. The second experiment studied the ignitability of thermoplastics under an imposed radiant heat flux. The ignition test apparatus consists of a conical spiral heating element positioned horizontally above the sample, a continuous spark ignition source and a removable heat shield. Experiments were conducted in a sealed pressure chamber on samples of either PMMA or POM, 1.5 mm thick, with a ceramic backing. There is some indication that gravity influences the time to ignition for some materials.     

Experimental study on the radiative ignition of silicones

Silicones comprise a wide variety of materials such as fluids, elastomers, resins, and foams. This paper reports the ignitability of some typical silicones under various external radiant heat fluxes. The ignitability of silicones was studied using a cone calorimeter under radiant heat flux levels of 0.5–60 kW m⁻². The time to ignition of the silicones was found to be proportional to a power of the incident heat flux that varies from −1.33 to −2.84. For silicone fluids, viscosity (or molecular size) is the key variable in controlling the ignitability. For silicone elastomers, the fillers play an important role in controlling the ignitability, especially at incident heat fluxes lower than 35 kW m⁻². The ignitability of silicone resins depends on the chemical structure of the resins: the pure trifunctional resin has the lowest ignitability. The ignitability of the silicone foams having the same density depends on the foam thickness, especially at incident heat fluxes lower than 30 kW m⁻². © 1998 John Wiley & Sons, Ltd.     

Flammability of oil‐based painted gypsum wallboard subjected to fire heat fluxes

The flammability of painted gypsum wallboard (GWB) exposed to fire heat fluxes is investigated. GWB samples coated with multiple layers of alkyd/oil‐based paint are subjected to constant incident heat fluxes of 35, 50 and 75 kW/m² in the Cone Calorimeter for periods of 5, 10 and 15 min. A number of coats of alkyd/oil‐based interior semi‐gloss enamel paint, including 1, 2, 4, 6 and 8 coats, are applied over a single coat of oil‐based primer to the exposed surface of 16 mm (5/8 in.) thick type X GWB. Unpainted type X GWB is also evaluated under the same exposure conditions. The potential for upward flame spread based on the Cone Calorimeter results is evaluated. The occurrence of paint ‘blistering’ is observed to have a significant effect on the time to ignition and consequently on the potential for upward flame spread. Further work is needed to evaluate the conditions under which ‘blistering’ will occur and its effects on the potential for surface flame spread on painted gypsum wallboard. Copyright © 2004 John Wiley & Sons, Ltd.     

A mechanistic method for scrutinising LIFT ignition data

The lateral ignition and flame spread test (LIFT) standard (ASTM E 1321‐97a) requires the Thermal Response correlation to be scrutinized for data points that violate the zero heat loss requirement, but the standard gives no guidance on how this should be done. The fundamentals of linear regression were reviewed and an unbiased and mechanistic algorithm for scrutinising LIFT ignition data without human intervention was developed. The algorithm produced reasonable results compared with human interpretation of exemplar test data taken from the literature. Copyright © 2010 John Wiley & Sons, Ltd.     

Comparison of test protocols for the standard room/corner test

As part of international efforts to evaluate alternative reaction‐to‐fire tests, several series of room/corner tests have been conducted. Materials tested were mostly different wood products but included gypsum board and a few foam plastics. This is a review of the overall results of related studies in which the different test protocols for the standard room/corner test were used. Differences in the test protocols involved two options for the ignition burner scenario and whether or not the ceiling was also lined with the test materials. The test materials were placed on three walls of the room in all the tests. The two burner scenarios were (1) 40 kW for 300 s followed by 160 kW for 300 s and (2) 100 kW for 600 s and 300 kW for 600 s. The 40 and 160 kW burner scenario without the ceiling lined did not provide a severe enough test for flashover to occur with fire‐retardant‐treated materials. Use of the 100 and 300 kW burner scenario without lining the ceiling provided the ability to differentiate between wood products with ASTM E 84 flame spread indexes of 70 to 125 and those with higher flame spread indexes. Lining the ceiling with test material creates a more severe test.     

Flame retarding effect of graphite in rotationally molded polyethylene/graphite composites

Linear low‐density polyethylene (LLDPE) compounds containing 10 wt % graphite fillers were rotationally molded into flat sheets. Flame retardancy was studied using cone calorimeter tests conducted at a radiative heat flux of 35 kW/m². Only the expandable graphite, an established flame retardant for polyethylene, significantly reduced the peak heat release rate. Compared with the neat polyethylene, it was easier to ignite the LLDPE composites containing carbon black, expandable graphite, and exfoliated graphite. However, rather unexpectedly, the inclusion of flake graphite increased the time to ignition by up to 80%. Simulations conducted with the ThermaKin numerical pyrolysis software suggest that increased reflectivity was mainly responsible for this effect. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41472.     

Burning plastics: Mechanisms of smoke formation

Quantitative pyrolysis gas chromatography studies have been conducted on three grades of cross-linked polyester resin formulated for improved resistance to surface spread of flame. Pyrolysis temperatures from 723 to 1273 K were used, and these values correspond to ‘surface’ temperatures of materials exposed to heat fluxed of 15–149 kW m^–2 which are typical of conditions experienced in real fires. Comparison is made with earlier macro studies on the evolution of smoke from plastics materials exposed to similar heat fluxes under an inert atmosphere. There is some correlation between the smoke obscuration data obtained in previous macro studies and the yield of volatile aromatic products evolved on pyrolysis. The presence of flame retardants increases the formation of carbon in the pyrolysis residue and decreases the yield of volatile aromatic products isolated. The results are considered in the context of mechanisms of smoke formation.