The integration of intumescent flame-retardant (IFR) additives in natural fiber-based polymer composites enhances the fire-retardant properties, but it generally has a detrimental effect on the mechanical properties, such as tensile and flexural strengths. In this work, the feasibility of graphene as a reinforcement additive and as an effective synergist for IFR-based flax-polypropylene (PP) composites was investigated. Noticeable improvements in tensile and flexural properties were achieved with the addition of graphene nanoplatelets (GNP) in the composites. Furthermore, better char-forming ability of GNP in combination with IFR was observed, suppressing HRR curves and thus, lowering the total heat release (THR). Thermogravimetric analysis (TGA) detected a reduction in the decomposition rate due to strong interfacial bonding between GNP and PP, whereas the maximum decomposition rate was observed to occur at a higher temperature. The saturation point for the IFR additive along with GNP has also been highlighted in this study. A safe and effective method of graphene encapsulation within PP using the fume-hood set-up was achieved. Finally, the effect of flame retardant on the flax-PP composite has been simulated using Fire Dynamics Simulator.
Keywords: computational fluid dynamics; encapsulation; fire retardant; mechanical properties; nano composite; natural fibers.