Intermediate-scale testing is indispensable when investigating the fire resistance under simultaneous compressive load of components made of glass- and carbon-fibre-reinforced composites (GFRP and CFRP). BAM is successfully operating an intermediate-scale test stand, developed for a specimen size of 500 mm x 500 mm (1000 mm). The fire resistance in terms of fire stability of CFRP and GFRP sandwiches are investigated, e.g. at 20 % of their compressive failure load at room temperature. Times to failure increase by up to a factor of 4 due to intumescent coatings. For GFRP sandwiches, different core structures with and without additional flame retardants show an astonishing impact on time to failure. CFRP shell structures are investigated on the intermediate scale with and without stringer reinforcements, resulting in completely different mechanical failure behaviour in the ultimate load test as opposed to the fire resistance test. The stringers become the only load-carrying part, while the shell acts as a protective layer. Thus the design exploiting this self-protection potential, i.e. the residue of the front skin protecting the load-bearing structure, is highlighted as a most promising route to enhance the fire resistance of lightweight materials.
Fire resistance testing of components made of carbon fibre reinforced polymers (CFRP) usually demands intermediate-scale or full-scale testing. A bench-scale test is presented as a practicable and efficient method to assess how different fire protective systems improve the structural integrity of CFRPs during fire. The direct flame of a fully developed fire was applied to one side of the CFRP specimen, which was simultaneously loaded with compressive force. Three different approaches (film, non-woven, and coatings) were applied: paper with a thickness in the range of μm consisting of cellulose nanofibre (CNF)/clay nanocomposite, nonwoven mats with thickness in the range of cm and intumescent coatings with a thickness in the range of mm. The uncoated specimen failed after just 17 s. Protection by these systems provides fire stability, as they multiply the time to failure by as much as up to 43 times. The reduced heating rates of the protected specimens demonstrate the reduced heat penetration, indicating the coatings’ excellent heat shielding properties. Bench-scale fire stability testing is shown to be suitable tool to identify, compare and assess different approaches to fire protection.
The fire stability of carbon fiber reinforced polymer (CFRP) shell structures was investigated using an intermediate-scale test setup. The shell specimens are representative of typical load-bearing CFRPs in modern civil aviation. The CFRP shell specimens were exposed to a fully developed fire with direct flame impingement to one side at a heat flux of 182 kW/m2. Specimens were simultaneously loaded with constant compressive force equal to 40% of the ultimate failure load. CFRP shells and four different fire retarding configurations, using integrated protective layers, were investigated. Unprotected CFRP specimens failed after just 27 s. Specimens with integrated protective layers with low heat conductivity and high burn-through resistance showed the most promising results. An integrated titanium foil decelerated the decomposition of the epoxy matrix and increased the time to failure by 68% compared to the unprotected CFRP shell.