Abstract
Zirconia (ZrO2)-based flame retardant coatings were synthesized through the process of grinding, mixing, and curing. The flame retardant coatings reinforced with zirconia nanoparticles (ZrO2 NPs) were prepared at four different formulation levels marked by F0 (without adding ZrO2 NPs), F1 (1% w/w ZrO2 NPs), F2 (2% w/w ZrO2 NPs), and F3 (3% w/w ZrO2 NPs) in combination with epoxy resin, ammonium polyphosphate, boric acid, chitosan, and melamine. The prepared formulated coatings were characterized by flammability tests, combustion tests, and thermogravimetric analysis. Finally, char residues were examined with scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). The peak heat release rate (PHRR) of the controlled sample filled with functionalized ZrO2 NPs was observed to decrease dramatically with increasing functionalized ZrO2 NPs loadings. There was an increase in the limit of oxygen index (LOI) value with the increase in the weight percentage of ZrO2 NPs. The UL-94V data clearly revealed a V-1 rating for the F0 sample; however, with the addition of ZrO2 NPs, the samples showed enhanced properties with a V-0 rating. Thermal gravimetric analysis (TGA) results revealed that addition of ZrO2 NPs Improved composite coating thermal stability at 800 °C by forming high residual char. The results obtained here reveal that the addition of ZrO2 NPs in the formulated coatings has shown the excellent impact as flame retardant coatings.
Highlights
ZrO2 material has good physical and chemical properties such as visually good color, high chemical stability, excellent anti-corrosive properties, high tensile strength, high hardness, and good mechanical and electrical properties [1,2]
The results obtained here reveal that the addition of ZrO2 NPs in the formulated coatings has shown the excellent impact as flame retardant coatings
Due to its high-temperature resistance, ZrO2 is used as filler in intumescent flame retardant coatings (IFRCs) [15,16,17]
Summary
ZrO2 material has good physical and chemical properties such as visually good color, high chemical stability, excellent anti-corrosive properties, high tensile strength, high hardness, and good mechanical and electrical properties [1,2]. Zirconia is used in a broad spectrum of applications, such as refractory products, ceramics, and electronic devices [3,4,5,6,7] It is widely utilized in corrosive environments, and zirconium alloys can be used in pipes, steel alloys, and flame retardant coatings. Another anomalous property of zirconia-based materials is their high strength and low thermal conductivity, and some of the zirconium-oxide-containing ceramics can conduct oxygen ions [8,9,10,11,12]. Due to its high-temperature resistance, ZrO2 is used as filler in intumescent flame retardant coatings (IFRCs) [15,16,17]
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