Research Progress on Ultra-high Temperature Ceramic Composites

doi:10.15541/jim20230609

Abstract

Abstract:

In response to the evolving landscape of high-speed aircraft, characterized by an expansive airspace, prolonged flight durations, and increased velocities, the thermal protection requirements for key structures such as the nose cone, leading edge, and engine combustion chamber have become more exacting. This necessitates a concerted focus on the development of high-performance thermal protection materials capable of withstanding extreme conditions. Ultra-high temperature ceramic composites have emerged as noteworthy candidates, showcasing exceptional oxidation and ablation resistance. Despite their commendable properties, the inherent brittleness of these composites poses a significant obstacle to widespread engineering applications. To address this limitation, there is a growing emphasis on toughening through structural modulation. Simultaneously, the imperative to enhance aircraft payload capacity underscores the demand for lightweight ultra-high temperature ceramic composites. This paper provides a systematic overview of the major research advances made in recent years on ultra-high temperature ceramic composites, including preparation methods such as pressure sintering, slurry infiltration, precursor impregnation and pyrolysis, reactive melt infiltration, chemical vapor infiltration/deposition, and “solid-liquid” combination process, toughening methods such as particles, whiskers, soft-phase materials, short-cut fibers, and continuous fibers, as well as oxidation ablation resistant properities and mechanisms, and lightweighting design. The relationship between the components, microstructures and properties of ultra-high temperature ceramic composites is discussed in depth, and the current challenges as well as the future development trends of ultra-high temperature ceramic composites are presented.

Key words: ultra-high temperature ceramic, composite, toughening, oxidation ablation resistance, lightweight, review

CLC Number:

TB332

ZHANG Xinghong, WANG Yiming, CHENG Yuan, DONG Shun, HU Ping. Research Progress on Ultra-high Temperature Ceramic Composites[J]. Journal of Inorganic Materials, 2024, 39(6): 571-590.

Figures/Tables 10

Fig. 1 Microstructures of 3D Cf/ZrC-SiC composites prepared by hot pressing sintering[31] (a, b) Carbon fiber surface at different magnifications; (c, d) Carbon fiber-ceramic interface at different magnifications

Fig. 2 Combustion chamber prepared by Ultramet using RMI[58]

Fig. 3 Microstructure characterization of “solid-liquid” combination process[70-71] (a, e) Microscopic comparison with/without vibration-assisted[70]; (b-d, f-h)Interfascicular (b-d) and intrafascicular (f-h) microstructures of fibers before (b, f) and after (c, d, g, h) densification[71]

Fig. 4 Densification mechanism and microstructure of "solid-liquid" combination process[71] (a) Mechanism of densification; (b) Microstructure after addition of polycarbosilane (PCS); (c) Microstructure after pyrolysis

Fig. 5 Additive manufacturing technologies for ultra-high temperature ceramic composite materials[75,78⇓ -80] (a) DLP printer[75]; (b) Schematic of SiO2/phosphate ceramic matrix composites fabricated by DIW[78]; (c) Schematic of Cf/SiC ceramic matrix composites fabricated by FDM[80]; (d) Examples of SiCf/ZrB2-SiC composites with ink being printed and pyrolytic structures fabricated[79]

Fig. 6 Mechanisms for toughening ultra-high temperature ceramic composites[71,85,87,90,93 -94,100,115] (a) Particle toughening[85]; (b) Whisker toughening[87]; (c) Graphene toughening[93]; (d) Graphite flakes toughening[90]; (e) Carbon nanotube toughening[94]; (f) Short cut fiber toughening[100]; (g) Continuous fiber toughening[71]; (h) Fibrous monolith structure toughening[115]

Fig. 7 Sugar-carbon conversion process and results[111] (a) Process; (b-g) Hydrothermal coatings with different thicknesses of (b) 70 nm, (c) 160 nm, (d) 300 nm, (e) 1 μm, (f) 1.3 μm, and (g) 1.8 μm

Fig. 8 Macro-micro characterization of ultra-high temperature ceramic composites against oxidative ablation (a) Cf/ultra-high temperature ceramic composites ablated under oxyacetylene flame after 30 and 60 s with diameter of 30 mm[118]; (b) Oxyacetylene ablation test[119]; (c) Arc jet plasma wind tunnel in German Aerospace Agency (DLR); (d) Microscopic morphology of ZrB2-SiC material after plasma wind tunnel ablation[120]; (e) Macroscopic morphologies of Cf/HfB2-SiC composites before and after oxyacetylene ablation[128]; (f-i) Micro-morphologies of Cf/HfB2-SiC composites after oxyacetylene ablation[128]

Fig. 9 Ablation mechanism of Cf/ZrC-SiC composites[135] (a) Oxide ablation mechanism; (b) Carbon fiber ablation mechanism; (c) PyC ablation microscopic morphologies

Fig. 10 Gradientised Cf/ultra-high temperature ceramic composites[128] (a) Long-distance and ultrafast antigravity transport of slurries inside the fibrous framework; (b) Images for gradiented C/ZrB2-SiC and C/HfB2-SiC; (c) SEM images of cross-profile for final Cf/ZrB2-SiC and Cf/HfB2-SiC composites

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