AbstractThermal Protection Systems (TPS) protect reâentry space vehicles from the harsh heating they encounter when hypersonically flying through a planet or the earth's atmosphere. Carbon fiberâreinforced phenolic resin composites were widely used for the thermal barrier structure of aerospace reâentry vehicles. A Novel Aluminium Titanate (Al2TiO5/AT) micro powderâmodified Polyacrylonitrile (PAN) based Carbon Fiber FabricâResorcinol Phenol Formaldehyde Resin (CâPR) (ATâCâPR) composites are well prepared to meet the requirements of TPS. The AT may act as an insulating layer and antiâablative material due to its excellent thermal shock resistance in TPS. To understand the effectiveness of AT content on density, barcol hardness, interfacial interactions, thermal conductivity, and thermal stability, the CâPR composites were produced with and without loading of AT with various weight percentages, namely 0 wt% (CâPR), 1,3, and 5 wt% (ATâCâPR) by hot compression molding method. The microstructural and elemental change of the composites were analyzed by microscopic and spectroscopic studies. Results suggested that the Interlaminar Shear Strength (ILSS) of the composites was increased by about 14% at 1 wt% of AT loading. Mass, Linear Ablation Rates (MAR, LAR), and backâface temperature of CâPR and ATâCâPR composites were decreased to 0.15128 g/s, 0.01233 mm/s, and 405°C, respectively by loading of AT up to 1 wt%. The thermally ablated composites were also evaluated for their crystallographic phase changes. The work provided an effective way to improve the thermoâmechanical and ablation performance characteristics of the ATâCâPR composites that can be potentially used in TPS of reâentry vehicles.Highlights This investigation utilized innovative Al2TiO5/Aluminium Titanate (AT) ceramic powder as a filler in reinforcing Phenolic Resin (PR) with PANâbased Carbon Fiber (C). It examined the impact of various loadings of AT in CâPR composites (ATâCâPR) on their physical, mechanical, thermal, and antiâablation properties. The ATâCâPR composites exhibit reduced density, lower thermal conductivity, and enhanced ILSS (31 MPa) compared to the CâPR composites. Optimal ablation resistance and thermal stability were achieved with a loading of 1 wt% AT (Mass Ablation Rate: 0.15128 g/s and Linear Ablation Rate: 0.01233 mm/s) compared to the CâPR composites. Microstructural and elemental analysis of the composites were conducted using microscopy and energyâdispersive spectroscopy, revealing the presence of oxides and carbides on the ablated surface. The phase transition and alterations in microstructure, coupled with the oxidation of AT, have enhanced the ablation resistance and reduced the back face temperature of different weight percentages of ATâCâPR composites, such as 1 wt% AT (413°C), compared to the CâPR composites (704°C).
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