Results are presented from an experimental study on the ignition of the combustion modified (fire retarded) polyurethane foam Pyrell® (35.3 kg/m3 and 64.0 kg/m3) in elevated oxygen concentrations, ranging from 30% to 60%. The samples are exposed to an external flow and variable radiant heat flux on one face, and insulated on the other faces. The experiments show that Pyrell undergoes a weak smoldering reaction that requires significant assistance in the form of external heat input in order to propagate. The results also show that given sufficient oxygen and radiant heat flux, the smoldering reaction can produce enough volatile fuel and heat to trigger a gas phase ignition, i.e. a transition from smoldering to flaming, in pores in the char region. The experiments also indicate that high-density Pyrell is more ignitable than low-density Pyrell, which could be explained by the greater solid surface area for smoldering reactions to take place.

Experimental observations are presented of the effect of flow velocity, oxygen concentration, and a thermal radiant flux, on the transition from smoldering to flaming in forward smoldering of small samples of polyurethane foam with a gas/solid interface. The experiments are part of a project studying the transition from smoldering to flaming under conditions encountered in spacecraft facilities, i.e., microgravity, low velocity variable oxygen concentration flows. Because the microgravity experiments are planned for the International Space Station, the foam samples had to be limited in size for safety and launch mass reasons. The feasible sample size is too small for smolder to self propagate because of heat losses to the surroundings. Thus, the smolder propagation and the transition to flaming had to be assisted by reducing heat losses to the surroundings and increasing the oxygen concentration. The experiments are conducted with small parallelepiped samples vertically placed in a wind tunnel. Three of the sample lateral-sides are maintained at elevated temperature and the fourth side is exposed to an upward flow and a radiant flux. It is found that decreasing the flow velocity and increasing its oxygen concentration, and/or increasing the radiant flux enhances the transition to flaming, and reduces the time delay to transition. Limiting external conditions for the transition to flaming are reported for this experimental configuration. The results show that smolder propagation and transition to flaming can occur in relatively small fuel samples if the external conditions are appropriate. The results also indicate that transition to flaming occurs in the char region left behind by the smolder reaction, and it has the characteristics of a gas-phase ignition induced by the smolder reaction, which acts as the source of both gaseous fuel and heat. A simplified energy balance analysis is able to predict the boundaries between the transition/no transition regions.

The transition from forward smoldering to flaming in polyurethane foam is observed using in-depth thermocouples and ultrasound probing. The experiments are conducted with small parallelepiped samples vertically placed in an upward wind tunnel. Three of the vertical sample sides are maintained at elevated temperature and the fourth is exposed to an upward oxidizer flow and a radiant heat flux. An ultrasound probing technique is used to measure the line-of-sight average permeability of the sample at the same heights as the thermocouples. The smolder front propagation is tracked by both the thermocouples and ultrasound data, which show an increase in temperature and permeability upon passage of the smolder front. The permeability data also show that the transition to flaming is preceded by rapid fluctuations in permeability in the char region below the smolder front, indicating the formation of pores by secondary char oxidation. The pores provide locations for the onset of gas-phase ignition (i.e. transition to flaming). The results from all the tests indicate that the formation of pores is a necessary but not sufficient condition for the transition to flaming. Two novel measures of the intensity of the secondary char oxidation are introduced: the time derivative of permeability, and the secondary char oxidation velocity. The time derivative of permeability, which provides a measure of the pore formation rate, is found to increase as the oxygen concentration and/or radiant heat flux increase, and to indicate the likelihood of the transition to flaming. The permeability data offers a means to track the propagation of the secondary char oxidation, and to calculate the secondary char oxidation velocity, which is found to be strongly correlated to the transition to flaming. A simplified energy balance model is able to predict the dependence of the secondary char oxidation velocity on oxygen concentration and radiant heat flux.