The effects of aluminum hypophosphite (AHP) as a synergistic agent on the flame retardancy and thermal degradation behavior of intumescent flame retardant polypropylene composites (PP/IFR) containing ammonium polyphosphate (APP) and triazine charring-foaming agent (CFA) were investigated by limiting oxygen index (LOI)

UL-94 measurement

thermogravimetric analysis (TGA)

cone calorimeter test (CONE)

scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). It was found that the combination of IFR with AHP exhibited an evident synergistic effect and enhanced the flame retardant efficiency for PP matrix. The specimens with the thickness of 0.8 mm can pass UL-94 V-0 rating and the LOI value reaches 33.5% based on the total loading of flame retardant of 24 wt%

and the optimum mass fraction of AHP/IFR is 1:6. The TGA data revealed that AHP could change the degradation behavior of IFR and PP/IFR system

enhance the thermal stability of the IFR and PP/IFR systems at high temperatures and promote the char residue formation. The CONE results revealed that IFR/AHP blends can efficiently reduce the combustion parameters of PP

such as heat release rate (HRR)

total heat release (THR)

smoke production rate (SPR) and so on. The morphological structures of char residue demonstrated that AHP is of benefit to the formation of a more compact and homogeneous char layer on the materials surface during burning. The analysis of XPS indicates that AHP may promote the formation of sufficient char on the materials surface and improve the flame retardant properties.