Successful utilization of thermosetting resins as ablative materials for heat shields in thermal protection systems (tps) has led to extensive development and exploration of newer contemporary materials, surpassing the conventional resins in terms of thermal and physical properties. these materials have been put to use for over 40 years in a broad range of applications and meet the requirements of thermal protection systems (tps), effectively. thermal protection systems have been employed in all nasa planetary entry probes, shielding them from the severe heating encountered during hypersonic flights. major organizations like the ministry of defence, india, nuclear research centres and space research organizations are in a constant pursuit of appropriate low density, tps material candidates, which can withstand prolonged thermal exposure and erosive forces. this had led to the exploration of phenolic resins as ablative composites due to their structural integrity and thermal stability. the present work has been steered in the direction of dihydric phenolic systems of resorcinol formaldehyde resins by advanced laboratories working for the defence and aerospace sector, supporting the ceaseless continuous development of effective ablative materials for re-entry. the research focuses on critical missions associated with re-entry probes, missile nozzles, wing flanges and ballistic aeroshells in space shuttle programs. these resins, in their pristine form prove to be a better ablator than conventional phenol formaldehyde. a novel 3 dimensional network of a dihydric resorcinol formaldehyde (rf) has been synthesized successfully by modification with a wide range of additives and ultra high temperature ceramics namely silicon carbide, boric acid, op-poss, carbon soot, butyl rubber, fly ash cenosphere and boron nitride via an effortless and facile polymerization technique. the ablation and thermal properties were investigated with primary and cheap, yet effective test methods like oxy-acetylene flame test, which explored ablation rates in terms of mass loss and dimensional change, showing curtailments upto 70% in some cases. the results were compared and contrasted with thermogravimetric analyses which gives a detailed thermograph on step-wise degradation and decomposition traits. x-ray diffraction studies affirm for the formation of insulative, turbostratic, carbonaceous char formed upon resin pyrolysis with peaks at 24 and 44 attributing to (002) and (100) for turbostratic carbon formed during pyrolysis. interesting morphologies of the sample after ablation were observed with fesem exposing glassy nanospheres, floral assimilations, fused glass forms in the periphery and porous char in the depleted zone. mathematical models and energy balance equations were idealized for the exchange in energies at the surface of the ablator. the results determine that modification of the 3d network of the resin justifies its competency to replace conventional materials demonstrating augmented ablation resistance with faster reaction mechanisms. laser ablation studies have also been performed in order to determine the energy required for laser ablation fruitful in laser weaponry attacks. hydrophobicity and interaction with water molecules have been studies via contact angle measurement correlated with atomic force microscopy imaging for surface topography. thus the rf resins containing various additives were precisely synthesized and characterized which exhibited improved thermal properties, ablation- protective behaviour, enhanced laser resistivity and hydrophobicity. the important strengths of present work find potential applications as ablative coatings for missile systems and can be extended to fire proofing materials.
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