Investigations on the Morphological, Mechanical, Ablative, Physical, Thermal, and Electrical Properties of EPDM-Based Composites for the Exploration of Enhanced Thermal Insulation Potential

The most widely used filler in EPDM-based thermal insulation materials is asbestos which is hazardous to health and environment. The main motivation of this study was to develop improved EPDM-based materials by partially or completely replacing asbestos with other fillers. EPDM-Esprene501A and EPDM-Keltan(®)4869DE were used and the effect of three fillers (vulkasil-C, asbestos, carbon fiber fabric) on mechanical, ablative, physical, thermal, and electrical performances have been investigated. Samples were divided into phase -1, -2, and -3 by compounding EPDM with various percentages of fillers and other necessary ingredients. It was observed that asbestos and carbon fiber in the absence of vulkasil-C did not import enough reinforcement to EPDM-matrix. Experimental evidence showed that presence of vulkasil-C has not only enhanced mechanical properties but also improved thermal and ablation performance of EPDM-based composites. The swelling index was found comparatively lower with vulkasil-C than that with other fillers. Among two EPDMs, EPDM-Esprene based composites have shown comparatively better performance. Among all (phase-1–3) samples, E100K0VA (phase-2) has shown greater mechanical (stress 3.89 MPa; strain 774%), ablative (linear 0.1 mm/s; mass 0.05 g/s), and thermal (material left 91.0%) properties. Overall findings indicated improved properties of EPDM in the presence of vulkasil-C and may help to develop better heat resistant materials.