Simultaneous requirements for thermal management and fire safety present significant challenges for organic coatings used in high-temperature industrial environments due to their inherently low thermal stability and high flammability. In this study, a...
Simultaneous requirements for thermal management and fire safety present significant challenges for organic coatings used in high-temperature industrial environments due to their inherently low thermal stability and high flammability. In this study, a multifunctional organic coating formulationwas designed using aluminum hydroxide [Al(OH)₃] as a flame-retardant additive and alumina (Al₂O₃) as a thermally conductive filler. By systematically varying the Al(OH)₃–Al₂O₃ composite ratio, an optimized composition was identified that achieves a balanced enhancement in both flame retardancy and thermal conductivity. Microstructural analysis confirmed uniform dispersion of the hybrid fillers, and standardized flammability tests demonstrated a dual protection mechanism: Al₂O₃ promotes effective heat dissipation under normal operating conditions, whereas the endothermic decomposition of Al(OH) ₃ suppresses ignition during fire exposure. Coatings containing only Al₂O₃ exhibited limited flame-suppressing capability, underscoring the essential role of Al(OH)₃ in achieving fire resistance. The optimized coating composition shows strong potential for application in energy storage systems, semiconductor equipment, petrochemical facilities, and other industrial sectors requiring simultaneous heat dissipation and fire protection. These findings offer a systematic framework for developing multifunctional organic coatings with enhanced thermal conductivity and flame-retardant performance.