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<p>This study examines the effect of alumina nanoparticles (ANPs) on the flame retardancy and thermal stability of carbon fiber-reinforced polymer (CFRP) composites processed using the vacuum assisted resin infusion microwave curing (VARIMC) technique. CFRPs containing 0–4 wt% ANPs were evaluated through rheological test, void fraction, cone calorimetry, Raman spectroscopy, DSC, TGA, UL-94 HB, DMA, and infrared thermography. Rheological results showed that the incorporation of ANPs in epoxy decreased the viscosity at all loadings, with reductions of 3.92%, 5.75%, 2.42%, and 1.63% at 10&#xa0;s⁻¹ and 3.81%, 5.46%, 2.10%, and 1.25% at 100&#xa0;s⁻¹ for 1, 2, 3, and 4 wt% ANP, respectively, relative to the virgin sample. Microwave curing enabled efficient resin infiltration, reducing voids from 1.53% in neat CFRPs to 0.96% at 4 wt% ANP, while strengthening interfacial bonding. At 4 wt% ANP, composites exhibited a 32% decrease in peak heat release rate, 45% lower total heat release, delayed ignition, and a 165% increase in flame retardancy index. Raman analysis further revealed enhanced graphitization of the residual char, with the I<sub>D</sub>/I<sub>G</sub> ratio decreasing from 1.61 for virgin CFRP to 1.15 at 4 wt% ANP. FTIR analysis of the post-combustion residues confirmed the formation of a mixed carbonaceous inorganic char structure, with Al–O related bands becoming more distinct at higher ANP loadings, supporting the enhanced condensed-phase barrier effect. TGA showed up to 21% char residue, DSC confirmed improved thermal stability, and UL-94 HB tests revealed minimal burn length with rapid self-extinguishment. Mechanical performance was also enhanced, with storage and loss moduli reaching 7226&#xa0;MPa and 1558&#xa0;MPa, respectively. These results demonstrate microwave-cured ANP/CFRPs as multifunctional materials for aerospace, automotive, and energy storage applications.</p> Graphical abstract <p></p>

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Microwave-cured CFRP composites with alumina: enhanced flame retardancy and thermal stability

  • 期刊论文

  • 发表日期：

    2026年5月25日

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  • Rishubh Gupta,
  • Sunny Zafar

摘要

This study examines the effect of alumina nanoparticles (ANPs) on the flame retardancy and thermal stability of carbon fiber-reinforced polymer (CFRP) composites processed using the vacuum assisted resin infusion microwave curing (VARIMC) technique. CFRPs containing 0–4 wt% ANPs were evaluated through rheological test, void fraction, cone calorimetry, Raman spectroscopy, DSC, TGA, UL-94 HB, DMA, and infrared thermography. Rheological results showed that the incorporation of ANPs in epoxy decreased the viscosity at all loadings, with reductions of 3.92%, 5.75%, 2.42%, and 1.63% at 10 s⁻¹ and 3.81%, 5.46%, 2.10%, and 1.25% at 100 s⁻¹ for 1, 2, 3, and 4 wt% ANP, respectively, relative to the virgin sample. Microwave curing enabled efficient resin infiltration, reducing voids from 1.53% in neat CFRPs to 0.96% at 4 wt% ANP, while strengthening interfacial bonding. At 4 wt% ANP, composites exhibited a 32% decrease in peak heat release rate, 45% lower total heat release, delayed ignition, and a 165% increase in flame retardancy index. Raman analysis further revealed enhanced graphitization of the residual char, with the ID/IG ratio decreasing from 1.61 for virgin CFRP to 1.15 at 4 wt% ANP. FTIR analysis of the post-combustion residues confirmed the formation of a mixed carbonaceous inorganic char structure, with Al–O related bands becoming more distinct at higher ANP loadings, supporting the enhanced condensed-phase barrier effect. TGA showed up to 21% char residue, DSC confirmed improved thermal stability, and UL-94 HB tests revealed minimal burn length with rapid self-extinguishment. Mechanical performance was also enhanced, with storage and loss moduli reaching 7226 MPa and 1558 MPa, respectively. These results demonstrate microwave-cured ANP/CFRPs as multifunctional materials for aerospace, automotive, and energy storage applications.

Graphical abstract