To further improve the oxidation resistance of polymer derived ceramic (PDC) composites in harsh environments, Cf/SiC/SiHfBOC composites were prepared by chemical vapor infiltration (CVI) and precursor impregnation pyrolysis (PIP) methods. The weight retention change, mechanical properties, and microstructure of Cf/SiC/SiHfBOC before and after oxidation in air were studied in details. Microscopic analyses showed that only the interface between the ceramics and fibers was oxidized to some extent, and hafnium had been enriched on the composite surface after oxidizing at different temperature. The main oxidation products of Cf/SiC/SiHfBOC composites were HfO2 and HfSiO4 after oxidation at 1500 °C for 60 min. Moreover, the weight retention ratio and compressive strength of the Cf/SiC/SiHfBOC composites are 83.97% and 23.88±3.11 MPa, respectively. It indicates that the Cf/SiC/SiHfBOC composites should be promising to be used for a short time in the oxidation environment at 1500 °C.

Finding the optimum balance between strength and toughness, as well as acquiring reliable thermal shock resistance and oxidation resistance, has always been the most concerned topic in the discussion of ultra-high temperature ceramic composites. Herein, PyC modified 3D carbon fiber is used to reinforce ultra-high temperature ceramic (UHTC). The macroscopic block composite with large size is successfully fabricated through low temperature sintering at 1300 °C without pressure. The prepared PyC modified 3D Cf/ZrC-SiC composites simultaneously possess excellent physical and chemical stability under the synergistic effect of PyC interface layer and low temperature sintering without pressure. The fracture toughness is increased in magnitude to 13.05 ± 1.72 MPa·m1/2 accompanied by reliable flexural strength of 251 ± 27 MPa. After rapid thermal shock spanning from room temperature (RT) to 1200 °C, there are no visible surface penetrating cracks, spalling, or structural fragmentation. The maximum critical temperature difference reaches 875 °C, which is nearly three times higher than that of traditional monolithic ceramics. The haunting puzzle of intrinsic brittleness and low damage tolerance are resolved fundamentally. Under the protection of PyC interface layer, the carbon fibers around oxide layer and matrix remain structure intact after static oxidation at 1500 °C for 30 min. The oxide layer has reliable physical and chemical stability and resists the erosion from fierce oxidizing atmosphere, ensuring the excellent oxidation resistance of the composites. In a sense, the present work provides promising universality in designability and achievement of 3D carbon fiber reinforced ceramic composites.

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To find the optimum balance between strength and toughness, as well as acquiring reliable thermal shock resistance and oxidation resistance, has always been the most concerned topic in the discussion of ultra-high temperature ceramic composites. Herein, PyC modified 3D carbon fiber is used to reinforce ultra-high temperature ceramic. The macroscopic block composite with large size is successfully fabricated through ultra-low temperature sintering at 1300°C without pressure. The prepared PyC modified 3D Cf/ZrC-SiC composites simultaneously possess excellent physical and chemical stability under the synergistic effect of PyC interface layer and ultra-low temperature sintering without pressure. The fracture toughness is increased in magnitude to 13.05 ± 1.72 MPa∙m1/2 accompanied by reliable flexural strength of 251 ± 27 MPa. After rapid thermal shock spanning from RT to 1200°C, there is no visible surface penetrating cracks, spalling or structural fragmentation. The maximum critical temperature difference reaches 875°C, which is nearly three times higher than that of traditional monolithic ceramics. The haunting puzzle of intrinsic brittleness and low damage tolerance are resolved fundamentally. Under the protection of PyC interface layer, the carbon fibers around oxide layer and matrix remain structure intact after static oxidation at 1500°C for 30 min. The oxide layer has reliable physical and chemical stability and resist the erosion from fierce oxidizing atmosphere, ensuring the excellent oxidation resistance of the composites. In a sense, the present work provides promising universality in designability and achievement of 3D carbon fiber reinforced ceramic composites.