On the Influence of Flame-Retardant Additives on UV-Curable Thermosetting Glass Fiber-Reinforced Composites

One of the main advantages of fiber-reinforced polymer (FRP) composites is the ability to reduce their weight while they exhibit exceptional properties such as high strength, stiffness, and resistance to corrosion, and reduction in their lifetime maintenance when they are compared to the metallic components. These features led fiber-reinforced polymer composites to have applications in the mechanical, construction, aerospace, automotive, medical, marine, and other manufacturing industries. However, the use of this type of material is not possible in all of these applications since, in certain sectors, the fire resistance property that the material must present is one of the key factors. For this reason, a thermosetting resin composed of ultraviolet (UV)-curable acrylic monomers has been used as a matrix, where transparent aluminum trihydrate (ATH) flame-retardant fillers were incorporated for manufacturing flame-retarded UV-curable composites. The composite parts were produced by using glass fiber-reinforced UV-curable prepregs. An exhaustive study of different types of ATH-based flame-retardant additives and the possible cooperation between them to improve the fire properties of the UV-curable composite was carried out. Additionally, the most suitable additive percentage to meet the railway sector requirements was also evaluated, as well as the evolution in the viscosity of the matrix and its processing capacity during the manufacture of the prepregs at 60 °C. The compatibility between the fillers and the matrix was assessed using a dielectric analysis (DEA). The fire properties of both the matrix and the final composite were established.