Preparation of carbon/carbon‐ultra high temperature ceramics composites with ultra high temperature ceramics coating

Abstract

In order to increase the oxidation resistance of carbon/carbon (C/C) composites at long‐term high temperature, C/C‐Ultra High Temperature Ceramics composites (UHTCs) with a dual‐layer UHTCs oxidation coating was successfully designed and fabricated. The microstructure and ablation resistance were investigated and discussed. After ablation in arc‐heated wind tunnel with temperature being 2200°C for 1000s, the mass ablation rate and linear ablation rate were −1.9 × 10−2 mg/cm2s and 2.9 × 10−5 mm/s, respectively. The formation of thermodynamically compatible oxide scale including ZrO2 skeleton and SiO2 or Zr–Si–O glass on the surface were mainly contributed to the excellent ablation resistance of the composite.

Preparation and mechanical characteristics of fine‐woven cloth and punctured felt preform Cf/C‐SiC‐ZrC composite

“…As it is believed PIP process could generate a homogeneous ceramic matrix, while CVI process could be a necessity process that protects the carbon fibers (CFs) from chemical erosion caused by the precursors during the pyrolysis process; there were so many studies applying a combination of CVI and PIP processes to form the composite matrix. [12][13][14] CVD process is a process which requires simple facilities but healing the pits and cracks of the substrate and generate a smooth composite surface, 15,16 which is a proven process to form a composite coating.…”

“…5,23,24 The carbon/ceramic composites have already been proved to possess good service reliability in the high-temperature oxidation environment. 14,25 For instance, the boron element could work at 1073 K 26 and the silicone element can be operated at temperatures over 1973 K. 1,25,27 The adhesive joint properties of fine-woven punctured preform composite with a needled preform composite and Cu-W alloy, as well as the ablation behavior of such composite, have been discussed by our research group. 22,28 However, the composite mechanical properties, especially for the complete set of failure behaviors, must be discussed.…”

“…Researchers have developed several methods to enhance the oxidation resistant properties of C/C, such as hot pressing, 4 chemical vapor infiltration (CVI), 5,6 precursor infiltration and pyrolysis (PIP), 1 and reactive melt infiltration (RMI) 7,8 to introduce ceramic elements into the matrix, chemical vapor deposition (CVD), 9,10 and spark plasma sintering 11 to generate the anti‐oxidation barrier coating. As it is believed PIP process could generate a homogeneous ceramic matrix, while CVI process could be a necessity process that protects the carbon fibers (CFs) from chemical erosion caused by the precursors during the pyrolysis process; there were so many studies applying a combination of CVI and PIP processes to form the composite matrix 12‐14 . CVD process is a process which requires simple facilities but healing the pits and cracks of the substrate and generate a smooth composite surface, 15,16 which is a proven process to form a composite coating.…”

“…Silicon carbide (SiC) and zirconium carbide (ZrC) are commonly used ceramic matrix and/or coating due to their high melting points and insensitivity to oxidation at elevate temperatures 5,23,24 . The carbon/ceramic composites have already been proved to possess good service reliability in the high‐temperature oxidation environment 14,25 . For instance, the boron element could work at 1073 K 26 and the silicone element can be operated at temperatures over 1973 K 1,25,27 .…”

Effect of fiber-oriented direction on mechanical and ablative performance of C/C-HfC-ZrC-SiC composites

“…Though C/C composites can be used for nozzles in the solid rocket motor for several seconds(>3000°C) [4][5][6], the future thermal protection systems require a much longer service time for materials that used under oxidizing, thermochemical erosion, and extreme scouring of high heat flux conditions. To enhance the anti-oxidation and ablative properties of C/C composites, ultra-high temperature ceramics (UHTCs) such as ZrB 2 , HfB 2, ZrC, HfC, and SiC are added into C/C composites [7][8][9][10][11][12][13][14][15]. On the one hand, the introduction of UHTCs can effectively improve the anti-scouring and ablative property of the matrix; on the other hand, the toughing effects of C/C skeleton can enhance the fracture toughness and thermal shock behavior of the composites, endowing the C/C-UHTC composites with better ablation and high-temperature properties above 2000°C.…”