Because of unique combination of properties, ultra high temperature ceramics (UHTCs) are considered the most suitable material for applications in extreme environments as in hypersonic flights, atmospheric reentry, and rocket propulsion system. Processing of UHTCs especially ZrB 2-based ceramic composites with additives offer advantages in terms of simple processing methodology and excellent properties. Processing route highly controls the ceramic properties. Present review share out systematically and explain the processing strategies of ZrB 2-based ceramic composites-conventional, hot press or spark plasma sintering and their effect on microstructure features, physical, and mechanical properties and tribological performance. Present review suggests that it is possible to process full dense ZrB 2-SiC ceramic composite with ultrafine or nano size particles via fast sintering technique like spark plasma sintering and gives better mechanical and wear resistant properties. K E Y W O R D S additives, ceramics, composites, conventional, spark plasma, wear 2510 | VERMA Et Al. the most promising candidate for leading edge material. It has high oxidation resistance as compared to other borides. UHTC prototype of a nose-cone produced and construction of strakes of space vehicles are shown in Figure 1B,C. Apart from their use in aerothermodynamics for extreme conditions, 14-18 UHTCs are also used in automotive applications as cutting tools, turbine blades, tube vanes, seals, bearings, wear guides, automotive engine components, nozzles, exhaust ducts, heat exchanger tubes, combustors, centrifuges, filters, substrates, air preheaters, wire drawing and extrusion dies, valve seats, high precision balls, bearings, plungers for chemical pumps. 19-21 ZrB 2 and ZrB 2-SiC composites are one of these class of ultra high temperature ceramic composites having incorporating SiC additions making the composite efficient in ultra-refractory properties by enhancing their oxidation resistance and the mechanical properties. 22-24 To increase strength, oxidation resistance, fracture toughness, and to prevent grain growth in ZrB 2 composite, SiC particles are added. SiC having strong covalent bond occur in many different crystal structures, called polytypes. 25-30 2 | SYNTHESIS AND DEVELOPMENT HISTORY OF ULTRA HIGH-TEMPERATURE CERAMICS Ultra high temperature ceramics (UHTCs) came into development in 1960s. 1 ZrB 2 has high hardness (>20 GPa), melting temperature (>3000°C), and elastic modulus F I G U R E 1 A, X43-A, a reusable hypersonic aerospace vehicle that would utilize UHTC leading edges and control surfaces; B, Image courtesy of NASA 9 Hot pressed UHTC nose-cone after shaping by EDM 12 ; C, Strakes (composed of three sections, each having a different UHTC composition) 18 [Color figure can be viewed at wileyonlinelibrary.com] Category Reaction Carbothermal ZrO 2 + B 2 O 3 + 5C → ZrB 2 + 5CO Borothermal ZrO 2 + 4B→ZrB 2 + B 2 O 2 Aluminothermal 3ZrO 2 + 3B 2 O 3 + 10Al → 3ZrB 2 + 5Al 2 O 3 Boro/Carbothermal Reduction 7ZrO 2 + 5B 4 C→7ZrB 2...