Experimental investigation and numerical modelling of the fire performance for epoxy resin carbon fibre composites of variable thicknesses

This paper applies a unique integrated approach to determine the flammability properties of a composite material (epoxy with carbon fibre) and compares its fire behaviour at two different thicknesses (2.1 and 4.2 mm) by performing small scale (thermo‐gravimetric analysis (TGA)/Fourier transform infrared radiation) and meso‐scale tests (cone calorimeter). For small‐scale tests, experiments were conducted in nitrogen using TGA coupled to gas analysis by Fourier transform infrared radiation. These results allow the determination of thermal stability, main degradation temperature and main gaseous emissions released during the thermal degradation. For meso‐scale tests, experiments were carried out using a cone calorimeter with sample dimensions of 100 × 100 mm at five heat fluxes (30, 40, 50, 60 and 70 kW/m²). The results show that the ignition time increases with an increase in the thickness of the material. Relative hazard classification of the fire performance of the current composites has also been compared with other materials using parameters obtained elsewhere. In addition, the effective ignition, thermal and pyrolysis properties obtained from the ignition and mass loss rate experiments for the 4.2‐mm thick samples were used in a numerical model for pyrolysis to predict well ignition times, back‐surface temperatures and mass pyrolysis rates for all heat fluxes as well as for the 2.1‐mm thick samples. Note that the ignition temperature obtained in the cone agrees with the main degradation temperature in the TGA. The flammability properties deduced here can be used to predict the heat release rate for real fire situations using CFD modelling. Copyright © 2016 John Wiley & Sons, Ltd.     

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.     

Thermal and chemical analysis of flammability and combustibility of fir wood in cone calorimeter coupled to FTIR apparatus

This paper deals with the thermal degradation of fir wood in a cone calorimeter under well‐ventilated atmosphere used with a piloted ignition. The thermal and chemical sample decompositions were studied with heat fluxes varying from 15 to 60 kW m^?2. With the cone calorimeter results and equations found in literature, the significant parameters of fir wood sample flammability and combustibility were deduced from ignition time (t_ig), mass loss and gas analysis. These parameters are thermal response parameter, critical heat flux, ignition surface temperature, thermal thickness, mass loss rate, thermal inertia, effective heat of combustion, heat release rate, heat of gasification and others. Moreover, during each experiment, the main gaseous species emissions were continuously and simultaneously monitored. Furthermore, the solid degradation and combustion process for fir wood were described in details. Experimental results from cone calorimeter were compared with data found in literature, and generally, a quite good accordance was found between the both sets of results. Copyright © 2013 John Wiley & Sons, Ltd.     

Burning behaviors of selected chlorosilanes and SiH‐containing siloxanes

Chlorosilanes are silanes containing the Si‐Cl functional group and SiH‐containing siloxanes are siloxanes containing the Si‐H functional group. Some chlorosilanes and SiH‐containing siloxanes present potentially high fire or explosion hazards during handling, storage, transport and process operations. Cone calorimeter tests have been used to study the burning behaviors of selected chlorosilanes and SiH‐containing siloxanes at various incident heat fluxes to simulate pool fire burning. The peak heat release rate of a silicon intermediate obtained from the cone calorimeter at 15 kW/m² incident heat flux was very close to that measured by a relatively large‐scale field test. The flammability of monochlorosilanes was similar to that of organic hydrocarbons having comparable volatility. The flammability of chlorosilanes descends in the order of monochlorosilanes, dichlorosilanes and trichlorosilanes. SiH‐containing siloxanes ignited faster than non‐SiH‐containing siloxanes because of the reactive silicon‐hydrogen linkages. The ignition of SiH‐containing siloxanes was much more violent than the ignition of non‐SiH‐containing siloxanes. The SiH‐containing siloxanes exhibited a lower peak heat release rate, less total heat released and a lower peak smoke extinction coefficient compared with non‐SiH‐containing siloxanes having comparable volatility. 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.     

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.     

Thermal and flammability properties of polypropylene/carbon nanotube nanocomposites

The thermal and flammability properties of polypropylene/multi-walled carbon nanotube, (PP/MWNT) nanocomposites were measured with the MWNT content varied from 0.5 to 4% by mass. Dispersion of MWNTs in these nanocomposites was characterized by SEM and optical microscopy. Flammability properties were measured with a cone calorimeter in air and a gasification device in a nitrogen atmosphere. A significant reduction in the peak heat release rate was observed; the greatest reduction was obtained with a MWNT content of 1% by mass. Since the addition of carbon black powder to PP did not reduce the heat release rate as much as with the PP/MWNT nanocomposites, the size and shape of carbon particles appear to be important for effectively reducing the flammability of PP. The radiative ignition delay time of a nanocomposite having less than 2% by mass of MWNT was shorter than that of PP due to an increase in the radiation in-depth absorption coefficient by the addition of carbon nanotubes. The effects of residual iron particles and of defects in the MWNTs on the heat release rate of the nanocomposite were not significant. The flame retardant performance was achieved through the formation of a relatively uniform network-structured floccule layer covering the entire sample surface without any cracks or gaps. This layer re-emitted much of the incident radiation back into the gas phase from its hot surface and thus reduced the transmitted flux to the receding PP layers below it, slowing the PP pyrolysis rate. To gain insight into this phenomena, thermal conductivities of the nanocomposites were measured as a function of temperature while the thermal conductivity of the nanocomposite increases with an increase in MWNT content, the effect being particularly large above 160 °C, this increase is not as dramatic as the increase in electrical conductivity, however.     

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.     

Thermo-physical properties of coal under transient conditions

Coal samples were obtained along the vertical axis in an eight-inch diameter experimental moving bed coal gasifier. This system had a throughput of half a tonne of sized (6 × 20 mm) coal per day. The specific heat and thermal conductivity were measured using the line heat-source method with a transient sample temperature. The coal sample was heated at a rate of 4 K/min during the property measurement. The heat capacity and thermal conductivity were obtained from an iterative fit of the experimental data to the heat conduction equation taking due account of the probe size and contact resistance. The apparatus was tested with samples of known properties such as alumina powder and glass micro-beads. The measurements reported here cover the range from 300–700 K. Effects of surface moisture and pyrolysis reactions can be identified. The results are compared with data in the literature measured at constant sample temperatures. The line source technique is well suited to transient property measurements.     

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.     

Combustion behaviour of polyurethane flexible foams under Cone Calorimetry test conditions

The first part of this study focuses on the effect of cone calorimeter test variables on polyurethane flexible foam properties such as ignitability, heat release rate, effective heat of combustion and mass loss. Three of the main commercial foam types were used, i.e. conventional slabstock foams, high-resilience slabstock foams and all-MDI (methylene diphenyldiisocyanate) moulded foams. A decrease in heat flux (down to 40%) with increasing distance from the conical heater was measured. As a consequence, results were found to depend to a large extent on the thickness and the melting behaviour of the foam samples. To achieve a sufficiently constant and uniform heat flux exposure, sample thickness had to be limited to 25 mm. In addition, repeatability was found to be good under various conditions, with percentage standard deviations for effective heat of combustion, peak rate of heat release and mass loss below 10%. Levels of radiant flux above 25 kW m^?2 were found to be very severe to test flexible polyurethane foams. Under such conditions, foams that show large differences in combustion performance in small-scale flammability tests performed almost identically in the cone calorimeter. In the second part of this study the effects of foam variables, such as foam type, density and melamine content, are defined. These effects were clearly pronounced at radiant flux levels of 15–25 kWm^?2. Density was found to be the key variable in controlling ignition resistance. In addition, high-resilience slabstock foams and all-MDI moulded foams performed better than conventional slabstock foams of the same density. Melamine addition resulted in a delay of ignition for all three foam types and an incomplete combustion, decreased heat release and effective heat of combustion in HR-slabstock and all MDI moulded foams. However, melamine is not effective as a heat sink in conventional slabstock foams. The different performance of the foam types under study can be explained by a different melting behaviour.     

Specimen heat fluxes for bench-scale heat release rate testing

When a specimen is testd for its heat release rate (HRR) behaviour using a bench-scale such as ISO 5660 or equivalent, one very important test condition is not pre-standaridized and must be set: the heat flux to be imposed on the specimen by the heater. The heat flux cannot be ligitimately standardized, since the value appropriately to be used will differ according to purpose or application. The present paper sets forth the considerations which should govern the correct choice of heat flux. A discussion is given of minimum ignitiability level; statistical variability at low heat fluxes; the ranges of heat fluxes associated with small actual ignition sources; the heat fluxes associated with fires away from the ignition sources, all the way up to fully-involved room fires; the application of the product; and the needs associated with mathematical modeling of room fires. Correlational approaches are also illustrated and contrasted to physics-based ones. Finally, the empirical nature of the present situation is emphasized. Judged from first principles, it would appear that successful prediction of room fire results from bench-scale test data would require both the testing at a large number of different heat fluxes and the use of algorithms to permit time-dependent interpolation. Such algorithms have been proposed; however, some very successful predictions are noted with much simpler techniques.     

Effects of variations in incident heat flux when using cone calorimeter test data for prediction of full‐scale heat release rates of polyurethane foam

The development of methods to predict full‐scale fire behaviour using small‐scale test data is of great interest to the fire community. This study evaluated the ability of one model, originally developed during the European Combustion Behaviour of Upholstered Furniture (CBUF) project, to predict heat release rates. Polyurethane foam specimens were tested in the furniture calorimeter using both centre and edge ignition locations. Input data were obtained using cone calorimeter tests and infrared video‐based flame area measurements. Two particular issues were investigated: how variations in incident heat flux in cone calorimeter tests impact heat release rate predictions, and the ability of the model to predict results for different foam thicknesses. Heat release rate predictions showed good agreement with experimental results, particularly during the growth phase of the fire. The model was more successful in predicting results for edge ignition tests than for centre ignition tests and in predicting results for thinner foams. Results indicated that because of sensitivity of the burning behaviour to foam specimen geometry and ignition location, a single incident heat flux could not be specified for generating input for the CBUF model. Potential methods to determine appropriate cone calorimeter input for various geometries and ignition locations are discussed. Copyright © 2014 John Wiley & Sons, Ltd.     

Experimental and numerical study of burning behaviors of flaxboard with intumescent coating and nanoparticles in the cone calorimeter and single burning item tests

This paper presents an experimental and numerical investigation of the effects of intumescent coating and nanoparticles on the burning behaviors of flaxboard. Virgin flaxboard samples and those coated with intumescent coatings (with/without nanoparticles) were tested in the cone calorimeter and single burning item (SBI) test. Experimental results show a significant increase in the time to ignition and also a reduction in the heat release rate by the intumescent coatings. In order to explain quantitatively and predict the effects of the intumescent coating, a global fractional factor (the ratio of the heat flux at the interface of the intumescent surface and the char layer of flaxboard to the surface heat flux when there is no intumescent coating layer) was introduced based on analytical solutions for charring materials. The fractional factor for the intumescent coatings was found by comparing predictions to the experimental data in the cone calorimeter test and, subsequently, was incorporated in an upward flame spread model, along with the ignition and thermal properties deduced from the ignition tests, to predict the burning rates in the SBI tests. Copyright © 2011 John Wiley & Sons, Ltd.     

Flammability hazards of typical fuels used in wind turbine nacelle

This study aims to develop a complete methodology for assessing flammability hazards of typical fuels (ie, transformer oil, hydraulic oil, gear oil, and lubricating grease) used in a wind turbine nacelle by combining different experimental techniques such as thermogravimetric analysis and cone calorimetry. Pyrolysis properties (onset temperature, temperature of maximum mass loss rate, and mass residue) and reaction‐to‐fire properties (ignition time, heat release rate, mass loss rate, and smoke release rate) were determined and used for a preliminary assessment of thermal stability and flammability hazards. Additional indices, for ignition and thermal behavior (effective heat of combustion, average smoke yield, and smoke point height, heat release capacity, fire hazard parameter, and smoke parameter, were calculated to provide a more advanced assessment of the hazards in a wind turbine. Results show that pyrolysis of transformer oil, lubricating grease, hydraulic oil, and gear oil occur in the range of 150°C to 550°C. Lubricating grease and transformer oil show the higher and lower thermal stabilities with maximum pyrolysis rate temperatures of 471°C and 282°C, respectively. The measured relation between ignition time and radiant heat flux agrees well with Janssens method (a power of 0.55). The aforementioned indices appear to provide a reasonable prediction of performance under real fire conditions according to a full‐scale fire test documented by Declercq and Van Schevensteen. The results of the study indicate that transformer oil is the easiest to ignite while lubricating grease is the most difficult to ignite but also has the highest smoke production rate; that transformer oil has the highest heat release rate while gear oil has the lowest; and that the fire hazard parameter is the highest for transformer oil and the smoke parameter is the highest for lubricating grease. The potential of this type of work to design safer wind turbines under performance‐based approaches is clearly clarified.     

Inherent flammability parameters—Room corner test application

It has been hypothesized that four parameters are solely responsible for a material's performance in a flammability scenario. This excludes effects of material physical integrity, i.e. melting, delamination, etc. They are (1) the critical heat flux below which piloted ignition cannot occur (CHF), (2) the ratio of heat of combustion to heat of gasification (HRP), (3) the thermal response parameter related to the thermal inertia and the ignition temperature (TRP), and (4) the available energy per unit area (AEP). The fire scenario controls the process by its initial heat flux and region of ignition. The hypothesis is applied to 54 tests of the ISO Room Corner Test to assess its validity. It is shown that these four parameters give good correlations in predicting the time to flashover and whether it occurs. In principle, different correlations could be developed for other scenarios of tests and fire configurations. Copyright © 2009 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.     

A milligram-scale flame calorimeter pyrolyzer system used to emulate burning of nonthermally thin solid samples

A new Milligram-scale Flame Calorimetry (MFC) pyrolyzer system was developed to approximate heating conditions experienced by material samples in gram-scale tests, such as cone calorimetry. The main features of this pyrolyzer system are a miniature flat heating coil embedded into a platform supporting the sample crucible. The use of a constant power rather than a constant heating rate operation mode distinguished the new MFC from the other mg-scale flammability test method—microscale combustion calorimetry (MCC). A series of tests was carried out using the new MFC, cone, and MCC on five synthetic polymers representing a wide range of flammability behavior. All methods produced similar solid residue yields. The MFC peak heat release rate (HRR) was found to correlate linearly with the cone peak HRR (R² = 0.93). The MCC peak HRR did not exhibit a strong correlation with the corresponding cone data. The new MFC was found to produce heat of combustion (HOC) values nearly identical to those measured in cone calorimetry. The MCC had a tendency to produce higher heats of combustion. Both MFC and MCC measured sample ignition temperatures that showed some correlation with the square root of the time to ignition measured in a cone calorimeter. The MFC airborne particular yield was found to correlate well (linear R² = 0.91) with the average specific extinction area measured in the cone tests. It was concluded that the newly designed MFC can deliver relatively accurate flammability measurements similar to cone calorimetry while using three orders of magnitude smaller samples.     

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.     

Numerical simulations of polymer pyrolysis rate: Effect of property variations

The mass loss rate (MLR) of poly(methyl methacrylate) (PMMA) exposed to known radiant fluxes is simulated with two recently developed numerical codes, the National Institute of Standards and Technology (NIST) Fire Dynamics Simulator (FDS) and the Federal Aviation Administration (FAA) ThermaKin. The influence of various material properties (thickness, thermal conductivity, specific heat, absorption of infrared radiation, heat of reaction) on mass loss history is assessed, via their effect on the ignition time, average MLR, peak MLR, and time to peak. The two codes predict the influence of material parameters on the MLR in the order of decreasing importance: heat of reaction, thickness, specific heat, absorption coefficient, thermal conductivity, and activation energy of the polymer decomposition. Changes in the material properties also influence the MLR curves by switching the sample from thermally thick to thermally thin. The two numerical codes are generally in very good agreement for their predictions of the MLR vs time curves, except when in‐depth absorption of radiation was important. Copyright © 2010 John Wiley & Sons, Ltd.