Synergistic Effect of Magnesium Borate Whiskers on Antidripping and Fire Resistance of Intumescent Flame Retardant Polypropylene Composites

The development of high-performance flame-retardant (FR) polypropylene (PP) with high mechanical integrity remains a challenge. Herein, we demonstrate a synergistic flame retardancy system for PP achieved via partial substitution of piperazine pyrophosphate (PAPP) with 1 wt.% magnesium borate whiskers (MBW) for improved flame retardancy, and thermal and mechanical properties. The optimized PP/24PAPP/1MBW exhibits exceptional FR performance, driven by the formation of a highly ordered, continuous phosphorus–boron hybrid char in the condensed phase. Cone calorimetry test results reveal an 80% reduction in peak heat release rate, a 54% reduction in total heat release, and a 33% reduction in total smoke production compared to neat PP, while the UL-94 test confirms a V-0 rating with complete suppression of flaming drips. Morphological study of the char residue using Raman spectroscopy and SEM attributes this performance to enhanced char graphitization and structural coherence enabled by boron-mediated cross-linking. More importantly, this transformative flame retardancy performance is achieved without severe compromise to mechanical properties, retaining over 89% of the original tensile strength. This work confirms the PAPP/MBW system as a highly efficient, low-additive approach to creating advanced fire-safe polymer composites for engineering applications.