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Inorganic Flame-Retardant Coatings Based on Magnesium Potassium Phosphate Hydrate
Sin-Nan Chen1, Ching Lin1, Hao-Lun Hsu1
1Department of Chemical and Materials Engineering, National Kaohsiung University of Science and Technology, Kaohsiung 807618, Taiwan.
This study developed a novel magnesium potassium phosphate hydrate-based flame-retardant coating (MKPC). The optimized MKPC coating effectively protects steel substrates from high temperatures and flame exposure, demonstrating excellent flame retardancy.
Area of Science:
- Materials Science
- Chemical Engineering
- Fire Safety Engineering
Background:
- Developing advanced flame-retardant coatings is crucial for enhancing fire safety in various applications.
- Magnesium potassium phosphate hydrate (MKPC) based materials offer potential as effective flame retardants due to their unique chemical properties.
- Existing coatings may lack comprehensive protection against extreme thermal and flame conditions.
Purpose of the Study:
- To formulate and characterize a novel magnesium potassium phosphate hydrate-based flame-retardant coating (MKPC).
- To evaluate the thermal, corrosion-resistant, mechanical, and flame-resistant properties of the developed MKPC.
- To determine the optimal composition of MKPC for superior performance on steel substrates.
Main Methods:
- Formulation of MKPC using dead-burnt magnesium oxide (magnesia), potassium dihydrogen phosphate (KH2PO4), wollastonite, vermiculite, aluminum fluoride, aluminum trihydroxide, and calcium carbonate.
- Analysis of coating properties using scanning electron microscopy, electrochemical corrosion testing, compression testing, thermogravimetric analysis, and freeze/thaw tests.
- Optimization of MKPC composition based on molar ratios and weight percentages of constituents.
Main Results:
- The optimal MKPC composition (magnesia/KH2PO4 molar ratio = 4) exhibited low thermal conductivity (0.19 W/m K), high compressive strength (10.5 MPa), and strong bonding strength (6.62 kgf/cm2).
- Mullite whiskers formed at high temperatures acted as a ceramic shield, enhancing mechanical strength and compactness.
- The optimized MKPC coating on steel demonstrated excellent flame retardancy, with back-surface temperatures below 200 °C after 1 hour and 420 °C after 3 hours of intense flaming (>1000 °C).
Conclusions:
- The developed magnesium potassium phosphate hydrate-based flame-retardant coating (MKPC) effectively enhances the fire safety of steel substrates.
- The coating's superior flame retardancy is attributed to the synergistic effects of its constituents and the formation of a protective ceramic shield.
- The optimized MKPC formulation meets stringent flame-resistance requirements, indicating its significant potential for industrial applications.
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