Effect of zirconia on ablation mechanism of asbestos fiber/phenolic composites in oxyacetylene torch environment

Abstract Micron-size zirconium oxide (ZrO2) was used to improve the thermal stability and ablation properties of asbestos fiber/phenolic composites and to reduce their final cost. ZrO2/asbestos/phenolic composites were prepared in an autoclave by the curing cycle process. The densities of the composites were in the range of 1.64–1.82 g/cm3. The ablation properties of composites were determined by oxyacetylene torch environment and burn-through time, erosion rates and back surface temperature in the first required 20 s. To understand the ablation mechanism, the morphology and phase composition of the composites were studied by scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction. Thermal stability of the produced materials was estimated by means of thermal gravimetric analysis, in air which consisted of dynamic scans at a heating rate of 10 °C/min from 30 to 1000 °C with bulk samples of about 23±2 mg. The thermal stability of the composites was enhanced by adding ZrO2. The results showed that the linear and mass ablation rates of the composites after adding 14 wt% ZrO2 decreased by 58% and 92%, respectively. The back surface temperature of a sample with 14% zirconia was 49% lower than that of pure composite. The SEM studies showed that, modified composites displayed much lower porosity than that of non-modified composite and the destruction of asbestos fibers was very low. On the other hand, it appeared that a thin melted layer of ZrO2 covered the surfaces of zirconia-containing composites.