Polymer-derived ZrB2/(SiC-AlN) Ceramic Composites: Fabrication and Performance

doi:10.15541/jim20260026

Abstract

Abstract:

In response to the demanding requirements of extreme high-temperature structural applications, such as thermal protection systems for hypersonic vehicles, ZrB₂/(SiC-AlN) ceramic composites were fabricated via a precursor- derived route using commercially available polycarbosilane and polyborozirconoxane, followed by hot-press sintering at 1950 ℃. X-ray diffraction results indicated the formation of hexagonal SiC and ZrB₂ phases after sintering, while no distinct AlN diffraction peaks were observed due to the formation of a SiC-AlN solid solution. Microstructural observations revealed that in situ formed ZrB₂ was uniformly dispersed within the SiC-AlN matrix, contributing to improved densification and inhibition of grain growth. The effects of precursor-derived ZrB₂ content on phase composition, microstructure, densification behavior, and mechanical properties of the composites were systematically investigated. Among the series of samples, the composite containing 25% ZrB₂ and 10% AlN (in mass) exhibited the lowest open porosity (0.6%), the highest flexural strength ((407±14) MPa), and the maximum fracture toughness ((5.8±0.1) MPa·m^1/2). This composition also exhibited effective short-term oxidation resistance in static air over the temperature range of 800-1000 ℃. The results demonstrate that the precursor-derived introduction of ZrB₂ is an effective approach to tailor microstructure and enhance the overall performance of polymer-derived SiC-AlN ceramic composites.

Key words: precursor-derived ceramic, nanocomposite, SiC-AlN solid solution, toughness, strength

CLC Number:

TQ174

ZHOU Yan, LIU Qikai, XIA Aidong, ZHANG Buhao, YIN Jie, HUANG Zhengren. Polymer-derived ZrB₂/(SiC-AlN) Ceramic Composites: Fabrication and Performance[J]. Journal of Inorganic Materials, 2026, 41(9): 1339-1348.

Figures/Tables 12

Fig. 1 XRD patterns of the samples pyrolyzed at different temperatures

Fig. 2 XRD patterns of hot-pressed ZrB2/(SiC-AlN) ceramic composites (P90A10, P65A10Z25, and P45A10Z45) at 1950 ℃

Fig. 3 (a, e, i) Polished surfaces, (b, c, f, g, j, k) fractured surfaces and (d, h, l) SiC grain size distributions of hot-pressed ZrB2/(SiC-AlN) ceramics

Table 1 Properties of the precursor-derived ZrB2/(SiC-AlN) composites

Label	Open porosity/%	Flexural strength/MPa	Fracture toughness/ (MPa·m^1/2)
P90A10	2.9	368±8	4.5±0.1
P65A10Z25	0.6	407±14	5.8±0.1
P45A10Z45	1.1	328±5	3.7±0.3

Fig. 4 (a, b) SEM images and (c-h) elemental mappings of the polished surface of P65A10Z25

Fig. 5 (a) Morphology and (b-f) elemental mappings of the fracture surface of SiC-AlN solid-solution

Fig. 6 Crack propagation path and characteristic features in P65A10Z25

Fig. 7 Oxidation results of the samples at different temperatures (a-c) Phase analyses of oxide layers; (d-f) Variation of unit area mass change with oxidation time

Fig. 8 Surface and macro morphologies (insets) of the samples after oxidation at different temperatures (a-c) P90A10: (a) 800 ℃, (b) 1000 ℃, (c) 1200 ℃; (d-f) P65A10Z25: (d) 800 ℃, (e) 1000 ℃, (f) 1200 ℃; (g-i) P45A10Z45: (g) 800 ℃, (h) 1000 ℃, (i) 1200 ℃

Fig. S1 Thermal analysis of the ZrB2 precursors

Fig. S2 Point-scan element distribution of the P90A10 sample

Fig. S3 Element distribution of the P65A10Z25 sample during surface scanning and point scanning

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Polymer-derived ZrB₂/(SiC-AlN) Ceramic Composites: Fabrication and Performance

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