Imrana I. Kabir

This work presents the design of a novel multi-component surface-coating system incorporating expandable graphite (EG), ammonium polyphosphate (APP), aluminium tri-hydroxide (ATH), alginate, and D-glucosamine hydrochloride (DGH). Importantly, the coated polyurethane (PU) foams demonstrated performance within the corresponding Hazard Level 3 limits for the measured parameters, including Maximum Average Rate of Heat Emission (MARHE), smoke density, and toxicity, providing preliminary indications of their potential for railway fire safety applications. Systematic variations in EG loading revealed substantial improvements in flammability metrics, with the EG-rich formulation achieving a limiting oxygen index (LOI) of 73%, MARHE of 18 kW m⁻², and significantly reduced smoke production. EG transformed the fire behaviour even at high external heat fluxes from flaming to self-extinguishing and only smouldering, promoting rapid formation of a dense, thermally insulating char. Combined interactions between EG, inorganic, and biobased additives reinforced char integrity, suppressed degradation rates, and enhanced condensed-phase protection. Thermogravimetric analysis confirmed increased residue yields (up to 52 weight percentage at 600 °C). Overall, this multi-functional coating offers a cost-effective, low-toxicity strategy for producing flame-resistant PU foams for demanding transportation and construction applications.

Polyurethane (PU) is a highly versatile class of polymer utilised in many industries, including the aerospace sector. In conjunction with its superior mechanical properties, chemical resistance, and durability, it can be highly flammable depending on its form. This poses a risk aboard aircraft, which contain numerous fire hazards and cramped cabin spaces, proving an obstacle for the evacuation of passengers in an emergency. Flame-retardant additives have proven to enhance the thermal properties of polyurethane, but their toxicity and tendency to degrade mechanical performance make them unappealing. This review addresses three main topics: (1) the basic synthesis and structure of PU and modification through additives; (2) types of PU, their properties, and applications in the aerospace industry; and (3) evaluation methodologies for characterising PU performance, studying mechanical properties and thermal degradation. Several key challenges remain, including understanding the long-term durability of modified PU, optimising between fire performance and mechanical properties, improving the sustainability of PU throughout its lifetime, and validating numerical simulation as a viable testing method. This review aims to guide future research on modified PU technology to achieve safer, high-performing, and sustainable solutions for the aerospace industry and beyond.

The evolution of tennis equipment is fundamentally linked to advances in materials science and engineering, which have enabled enhanced player performance through optimised racquet and string designs. This review comprehensively examines the critical role of modern composite materials, manufacturing methods, and string technologies in tennis equipment, focusing on how these elements influence mechanical performance and player experience. It first explores the contributions of matrix and reinforcing materials, particularly carbon fibre and aramid composites, to racquet stiffness, strength, and vibration damping. Next, it details advanced manufacturing techniques such as prepreg layup, autoclave curing, and hollow moulding, which enable precise control over mechanical properties and quality assurance. This paper further evaluates various string materials including natural gut, Kevlar, polyester, nylon, and emerging hybrid setups, analysing their mechanical characteristics, tension maintenance, and impact on ball response and player comfort. Special attention is given to the interaction between design choices and playing conditions, such as court surfaces and player sensitivity, underscoring the complex interplay between equipment mechanics and gameplay dynamics. Through an interdisciplinary lens, this paper synthesises current scientific knowledge and experimental findings, providing a critical foundation for optimising tennis equipment design. By integrating materials science with practical application, this paper provides a comprehensive understanding of tennis equipment design, identifying gaps in current research and offering insights to guide future innovation for manufacturers, coaches, and players.

The growing demand for durable, fire-resistant, and sustainable pavements has intensified research on asphalt as a polymeric composite system. This review provides a comprehensive analysis of asphalt from the perspective of polymer science, focusing on (1) material composition: asphalt chemistry and polymer–binder interaction, and the introduction of polymer modifiers; (2) material properties: rheology, thermal stability, mechanical properties and flame retardancy; and (3) evaluation methods: derivative thermogravimetric analysis, cone calorimeter, scanning electron microscope and computer simulation. Applications in road infrastructure, industrial surfaces, and high-temperature environments are discussed, emphasizing how polymer modifications enhance performance under operational stresses. Evaluation methodologies, including wheel-tracking tests and thermogravimetric and derivative thermogravimetric analysis, are critically reviewed to quantify deformation, thermal degradation, and fire-resistance mechanisms at both microstructural and molecular levels. Several key challenges remain, including understanding the long-term interaction between polymers and asphalt, optimizing the dispersion of reinforcing materials, and maximizing the performance of recycled polymers. This review aims to guide future research on polymer-modified asphalt systems to achieve safer, more durable, and more sustainable pavement solutions.

As the demand for high-performance polymers broadens, polyurethane (PU) polymers with various chemical modifications have attracted attention. This review explores the chemical structure and functional variations of PUs. PUs are used in a variety of fields, ranging from aerospace engineering to daily necessities, and show remarkable safety adaptability through designable synthesis processes. This study is divided into four main parts: (1) synthesis and structure, covering the synthesis of PU base and modification of additive compounds; (2) performance, studying physical properties and thermal degradation processes; (3) application, evaluating the commercial potential of PU polymers; and (4) flame retardancy, analyzing five established flame-retardant mechanisms. The last part discusses how PUs can meet sustainable development goals by replacing petroleum-based materials with green materials. By emphasizing non-petroleum resources and novel, sustainable modification strategies, this review conducts guidance for the safe and environmentally friendly application of PUs in the future.

Polyurethane (PU) foam has a high flammability and is widely used in aircraft interiors, presenting a significant danger to occupants. This study analysed three composite intumescent flame-retardant (IFR) coatings for flexible PU foam; expandable graphite (EG), ammonium polyphosphate (APP) and alginate (AG). The coatings were prepared in concentrations of 5 wt%, 10 wt%, and 50 wt% with an acrylic binder. The coated samples were characterised using cone calorimetry, SEM, and mechanical testing. The findings showed peak heat release rate, total heat release, and carbon dioxide production from the 10 wt% triple-layer coating (EG:APP:AG) was 52%, 32%, and 58% less than the PU control. The char of the 10 wt% triple-layer sample effectively suppressed smoke release and inhibited the transfer of fuel and gas volatiles. Mechanical testing demonstrated a 3.4 times increase in tensile strength and a 15.4 times increase in compressive strength (50% compression) compared to the control PU with the 10 wt% triple-layer coating. A fire dynamics simulator model was developed that demonstrated large-scale flammability modelling for commercial aircraft. Future work can explore the integration of IFR coatings into computational analysis. These new bio-based coatings produced promising results for aircraft fire safety and flammability performance for PU polymers.

The effect of varying the weight percentage composition (wt.%) of low-cost expandable graphite (EG), ammonium polyphosphate (APP), fibreglass (FG), and vermiculite (VMT) in polyurethane (PU) polymer was studied using a traditional intumescent flame retardant (IFR) system. The synergistic effect between EG, APP, FG, and VMT on the flame retardant properties of the PU composites was investigated using SEM, TGA, tensile strength tests, and cone calorimetry. The IFR that contained PU composites with 40 wt.% EG displayed superior flame retardant performance compared with the composites containing only 20 w.t.% or 10 w.t.% EG. The peak heat release rate, total smoke release, and carbon dioxide production from the 40 wt.% EG sample along with APP, FG, and VMT in the PU composite were 88%, 93%, and 92% less than the PU control sample, respectively. As a result, the synergistic effect was greatly influenced by the compactness of the united protective layer. The PU composite suppressed smoke emission and inhibited air penetrating the composite, thus reducing reactions with the gas volatiles of the material. SEM images and TGA results provided positive evidence for the combustion tests. Further, the mechanical properties of PU composites were also investigated. As expected, compared with control PU, the addition of flame-retardant additives decreased the tensile strength, but this was ameliorated with the addition of FG. These new PU composite materials provide a promising strategy for producing polymer composites with flame retardation and smoke suppression for construction materials.

Building polymers are highly flammable and produce a vast amount of toxic chemical compounds in the event of a fire which can lead to potential incapacitation and death. To gain an in-depth understanding of this issue, smoke toxicity and thermal characteristics of seven commonly used building polymers were analysed through a systematic fire performance evaluation system using a Thermogravimetric Analyzer and a Cone Calorimeter coupled with an FTIR arrangement. Four Fractional Effective Dose (FED) expressions were compared to assess the smoke toxicity of the fire effluents based on different assumptions. It was found that FED_N2, calculated using Purser’s equation, reported the highest values of FED with the following order of potential smoke toxicity at 50 kW/m² radiative heat flux: LDPU > HDPU > PE > HDEPS > XPS > EVA > LDEPS. Furthermore, fire performance evaluation of the polymers was carried out by considering three key fire risk parameters, i.e., flashover propensity, total heat released, and toxic hazard. At 50 kW/m² radiative heat flux, HDPU exhibited 11.7 times flashover propensity compared to the least flammable polymer (HDEPS), EVA exhibited 5 times total heat release compared to the polymer with the lowest total heat release (LDEPS) and, LDPU exhibited 6.7 potential times toxic hazard compared to the least toxic polymer (EVA).

Ultra-small-angle neutron scattering (USANS) and small-angle neutron scattering (SANS) measurements, covering length scales from micrometres to nanometres, were made to investigate the structure of nanodiamonds (NDs) and their suspensions. These nanodiamonds were produced by two different techniques, namely by the detonation method and by the laser ablation of a carbon–hydrocarbon mixture. The (U)SANS results indicated the presence of structures four orders of magnitude larger than the dimensions of a single ND particle, consisting of aggregations of ND particles. This aggregation of the ND particles was studied by employing the contrast variation technique. Two different solvents, namely H₂O and dimethyl sulfoxide (and their deuterated counterparts), were used to understand the role of hydrogen in the shape and size of the aggregates. The analysis of experimental data from SANS measurements also reveals the ND particles to have an ellipsoidal structure. Using a defined shape model and the SANS contrast variation technique, it was possible to characterize the non-diamond outer shell of the particles and determine the outer layer thickness. This clarification of the structure of the NDs will allow better preparation of suspensions/samples for various applications. Understanding the structure of NDs at multiple length scales also provides crucial knowledge of particle–particle interaction and its effect on the aggregation structures.