Characterization of the carbonization process of expandable graphite/silicone formulations in a simulated fire

The fire performance of curable-silicone based coatings containing expandable graphite (EG) is evaluated in hydrocarbon fire scenario (standard UL1709) using a lab-scale furnace test. From 5% to 25% of expandable graphite is incorporated in the silicone matrix to make the coating swell during the fire experiment. Fire performance of 25%EG/silicone-based coating is better than that of commercial intumescent paint used as reference. This is explained by a high swelling velocity (18%/s), a high expansion (3400%), an impressive cohesion of the char and a low heat conductivity at high temperature (0.35 W/K m at 500 °C). To elucidate this way of charring, the residue after fire testing was analyzed by scanning electron microscopy, transmission electron microscopy, energy dispersive spectrometry, X-ray photoelectron spectroscopy and X-ray diffraction. It is shown that the char is composed of two main parts: the top is composed of quartz and amorphous silica which coat graphite flakes and the heart of the char is composed of graphite flakes embedded in degraded silicone forming a complex structure. It is shown that, the good cohesion of the char is due to: (i) the presence of the undegraded silicone matrix; and (ii) the coating of graphite pellets by silicone.