EPDM-based heat-shielding materials modified by hybrid elastomers of silicone or polyphosphazene

The erosion resistances of ethylene propylene diene monomer (EPDM) insulations are often inadequate for advanced solid rocket motor (SRM) applications. EPDM modification by blending secondary matrixes is a feasible approach to improve the ablative properties of EPDM insulations. The addition of flexible inorganic hybrid rubbers as a secondary matrix, such as silicones and polyphosphazenes, may impart EPDM insulations with better ablative performance. The blends of EPDM/hybrid rubbers represent the state-of-the-art heat-shielding materials for SRM. In the present work, methyl-phenyl silicone/EPDM and poly(diaryloxyphosphazene)/EPDM insulation systems with various blending ratios of secondary matrixes have been prepared. The ablative properties of the insulations were examined by oxy-acetylene ablation tests, and the results showed that these properties could be enhanced accordingly by blending with hybrid rubbers under appropriate proportions. The unique charred layers resulting from the hybrid rubbers contributed to their excellent ablation properties. For example, the silicone/EPDM insulations exhibited a more significant improvement of ablation resistance properties. With a 1:1 blending ratio of silicone/EPDM, the linear ablation rate was 0.06 mm s⁻¹ after 20 s of oxy-acetylene ablation. The enhancement in the ablative resistance was attributed to the charred layers with bunches of embedded compact microtubes with a length of 2–3 mm, which consisted of silicon carbide, silicon dioxide, and Si–O–C ceramics.