A new high-temperature method for the deposition of gas-tight silicon carbide protective coatings with low gas permeability has been developed. The free carbon atoms form during the high-temperature pyrolysis of hydrocarbon molecules. In turn, carbon reacts with molten silicon contained in the subsurface substrate layers and/or with silicon vapor. The source of silicon vapor serves the molten silicon in the heated zone of a reactor furnace. Such coatings effectively protect SiC-C-Si and SiC-C-MoSi2 ceramics, carbon–carbon composite materials, structural graphite, and refractory metals and alloys from oxidation. The conducted tests show the high thermal oxidation and thermal shock stability of deposited protective coatings, as well as their good adhesion to the substrates.

Silicon carbide (SiC) possesses a unique combination of properties such as high mechanical strength at elevated temperatures, wear resistance, low thermal expansion coefficient, high temperature oxidation resistance, corrosion stability, radiation hardness, high chemical inertness, and thermal conductivity. Unfortunately, SiC is very brittle and cannot, therefore, be used “as is”. SiC’s crack resistance, due to the prevention of crack propagation, can be increased by the reinforcing of SiC. In this paper, a novel method for manufacturing SiC-based composites reinforced with Mo wire is developed. The composites are produced by infiltrating porous carbon blanks with molten silicon. The molten silicon reacts with the molybdenum wire embedded in the carbon blanks. As a result, a complex interfacial silicide layer with a predominant MoSi2 phase is formed on the surface of the Mo wire. In addition, a thin layer of Mo5Si3 is formed between the residual metal in the core of the wire and the disilicide. A stable bond of the interfacial layer with both the residual metal and the SiC-based ceramic matrix is observed. Mechanical tests on the obtained samples for three-point bending at 20 and 1500 °C showed quasi-plastic damage. The reinforcing elements act as stoppers for propagating cracks in the event of a matrix failure. The developed method for producing composites with a ceramic matrix reinforced with metal wire makes it possible to reduce the cost of machining and manufacturing products with complex geometric shapes. It also opens the way for broader applications of SiC-based composites.