Preparation, mechanical properties and anti-oxidation behavior of lightweight porosity-controlled SiC(rGO, xZrB2) composite PDCs for thermal protection

Abstract

Achieving well-balanced light weight with simultaneous improvement in mechanical and antioxidant properties of SiC-based composite polymer-derived ceramics (PDCs) for hypersonic vehicle components is still a huge challenge. Herein, lightweight SiC(rGO, xZrB2) composite PDCs were prepared via re-pyrolyzing ball-milling-induced ZrB2-SiC(rGO)p/polycarbosilane-vinyltriethoxysilane-graphene (PCS-VTES-GO, PVG) blends. Main reinforcements consist of ZrB2, ZrO2(ZrC), ZrOSi and SiO2/β-SiC phases, among which favorable compatibility enables enhanced bear loading performances and high-temperature oxidation resistance. Rigid SiC(rGO)p tightly links with flexible PVG pyrolysis products, and co-assembles into robust SiOxCy/Cfree(rGO) matrix in framework owing to plentiful Si-dangling bonds at their interfaces. More interestingly, interfacial ZrOSi/ZrC transition zone can augment structural disorder of ceramic network, give bridging effects, strengthen interfacial compatibility, and even hinder further crack propagation for self-densification. Particularly, SiC(rGO, 30%ZrB2) composite PDCs possess optimal hardness (6.49 GPa) and outstanding fracture toughness (5.77 MPa⋅m1/2). Porous SiC(rGO, 30%ZrB2) composite PDCs own stable structure integrity within 60-min testing under butane torch flame at 1300 °C. Self-healing protective SiO2-ZrO2 glass layer avoids destructive structure and timely covers defects, thus retains good mechanical performances. Such good synergistic reinforcement and multiscale design of porosity-controlled composite, realizes integration of lightweight/good load-bearing characteristics with improved oxidation resistance for thermal protection system (TPS) of hypersonic vehicles.