scholarly journals Fabrication of C/C–SiC–ZrB2 Ultra-High Temperature Composites through Liquid–Solid Chemical Reaction

Crystals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1352
Author(s):  
Qian Sun ◽  
Huifeng Zhang ◽  
Chuanbing Huang ◽  
Weigang Zhang
Keyword(s):  
High Temperature ◽  
Ceramic Composites ◽  
Dense Matrix ◽  
Ablation Resistance ◽  
The Matrix ◽  
Melt Infiltration ◽  
Reactive Melt Infiltration ◽  
Reactive Melt ◽  
Diffusion Precipitation ◽  
Ultra High Temperature

In this paper, we aimed to improve the oxidation and ablation resistance of carbon fiber-reinforced carbon (CFC) composites at temperatures above 2000 °C. C/C–SiC–ZrB2 ultra-high temperature ceramic composites were fabricated through a complicated liquid–solid reactive process combining slurry infiltration (SI) and reactive melt infiltration (RMI). A liquid Si–Zr10 eutectic alloy was introduced, at 1600 °C, into porous CFC composites containing two kinds of boride particles (B4C and ZrB2, respectively) to form a SiC–ZrB2 matrix. The effects and mechanism of the introduced B4C and ZrB2 particles on the formation reaction and microstructure of the final C/C–SiC–ZrB2 composites were investigated in detail. It was found that the composite obtained from a C/C–B4C preform displayed a porous and loose structure, and the formed SiC–ZrB2 matrix distributed heterogeneously in the composite due to the asynchronous generation of the SiC and ZrB2 ceramics. However, the C/C–SiC–ZrB2 composite, prepared from a C/C–ZrB2 preform, showed a very dense matrix between the fiber bundles, and elongated plate-like ZrB2 ceramics appeared in the matrix, which were derived from the dissolution–diffusion–precipitation mechanism of the ZrB2 clusters. The latter composite exhibited a relatively higher ZrB2 content (9.51%) and bulk density (2.82 g/cm3), along with lower open porosity (3.43%), which endowed this novel composite with good mechanical properties, including pseudo-plastic fracture behavior.

Reactive Melt Infiltration of Carbon Fiber Reinforced Ceramic Composites for Ultra-High Temperature Applications

2013 ◽  
pp. 323-353
Author(s):  
Bai Shuxin ◽  
Tong Yonggang ◽  
Ye Yicong ◽  
Zhang Hong
Keyword(s):  
High Temperature ◽  
Carbon Fiber ◽  
Chemical Vapor Infiltration ◽  
Future Research ◽  
Fiber Reinforced ◽  
Melt Infiltration ◽  
Carbon Fiber Reinforced ◽  
Reactive Melt Infiltration ◽  
Reactive Melt ◽  
Ultra High Temperature

Carbon fiber reinforced ultra high temperature ceramic matrix composite (C/UHTC) is one of the most promising structural materials capable of prolonged operation in oxidizing environment at ultra high temperatures above 2000 ?C. Reactive melt infiltration (RMI) is a viable processing choice for C/UHTC composite. Compared with chemical vapor infiltration (CVI) and polymer impregnation and pyrolysis (PIP), RMI does not suffer from the drawbacks of time-consuming and high cost. It is viewed as a promising means of achieving near-net shape manufacturing with quick processing time and at low cost. Recently, great efforts have been made on RMI process for C/UHTC composite. Carbon fiber reinforced ZrC, HfC and TiC composites have been successfully fabricated by RMI. The aim of the following chapter is to introduce the RMI process and summarize the progress in RMI process for C/UHTC composite. In addition, future research directions of RMI are also proposed.

AERO-THERMO-DYNAMIC STUDY OF ULTRA-HIGH- TEMPERATURE CERAMIC COMPOSITES FOR THERMAL PROTECTION SYSTEMS AND ROCKET NOZZLES

2021 ◽  
Author(s):  
STEFANO MUNGIGUERRA ◽  
ANSELMO CECERE ◽  
RAFFAELE SAVINO
Keyword(s):  
High Temperature ◽  
Thermal Protection ◽  
Ceramic Composites ◽  
Thermal Protection Systems ◽  
Research Activities ◽  
Ablation Resistance ◽  
Protection Systems ◽  
Project Objectives ◽  
Ultra High Temperature

The most extreme aero-thermo-dynamic conditions encountered in aerospace applications include those of atmospheric re-entry, characterized by hypersonic Mach numbers, high temperatures and a chemically reacting environment, and of rocket propulsion, in which a combusting, high-pressure, supersonic flow can severely attack the surfaces of the motor internal components (particularly nozzle throats), leading to thermo-chemical erosion and consequent thrust decrease. For these applications, Ultra-High-Temperature Ceramics (UHTC), namely transition metal borides and carbides, are regarded as promising candidates, due to their excellent high-temperature properties, including oxidation and ablation resistance, which are boosted by the introduction of secondary phases, such as silicon carbide and carbon fibers reinforcement (in the so-called Ultra-High- Temperature Ceramic Matrix Composites, UHTCMC). The recent European H2020 C3HARME research project was devoted to development and characterization of new-class UHTCMCs for near-zero ablation thermal protection systems for re-entry vehicles and near-zero erosion rocket nozzles. Within the frame of the project and in collaboration with several research institutions and private companies, research activities at the University of Naples “Federico II” (UNINA) focused on requirements definition, prototypes design and test conditions identification, with the aim to increase the Technology Readiness Level (TRL) of UHTCMC up to 6. Experimental tests were performed with two facilities: an arc-jet plasma wind tunnel, where small specimens were characterized in a relevant atmospheric re-entry environment (Fig.1a), and a lab-scale hybrid rocket engine, where material testing was performed with different setups, up to complete nozzle tests, in conditions representative of real propulsive applications (Fig.1b). The characterization of the aero-thermo-chemical response and ablation resistance of different UHTCMC formulations was supported by numerical computations of fluiddynamic flowfields and materials thermal behavior. The UNINA activities provided a large database supporting the achievement of the project objectives, with development and testing of full-scale TPS assemblies and a large-size solid rocket nozzle.

THERMO-KINETIC STUDIES FOR FORMATION OF CARBON MATRIX - PRECURSOR FOR REACTIVE MELT INFILTRATION

1970 ◽  
Vol 61 (11) ◽  
Author(s):  
Maxim A. Khaskov ◽  
Alexey M. Shestakov ◽  
Stanislav D. Sinyakov ◽  
Oleg Yu. Sorokin ◽  
Artem I. Gulyaev ◽  
...  
Keyword(s):  
Mass Loss ◽  
Phenol Formaldehyde ◽  
Mass Loss Rate ◽  
Gelation Time ◽  
Carbon Matrix ◽  
Formaldehyde Resin ◽  
The Matrix ◽  
Melt Infiltration ◽  
Reactive Melt Infiltration ◽  
Reactive Melt

The formation of carbon matrix precursors for reactive melt infiltration was studied by thermal analysis and thermokinetics. It was shown, that pore-forming agent (ethylene glycol) slows down the exothermal reaction of phenol formaldehyde resin curing, while the addition of catalyst (4-toluenesulfonyl chloride) makes it possible to gelate the matrix before low-molecular product evaporation. It was shown, that gelation takes place without sufficient mass loss and results in disappearance of exothermal effect of curing at 50-100 °С. The gelation time of the system, which is equal to 47 min at 60 °С, was chosen as a time necessary for structure formation due to polymerization induced phase separation. Post-curing of thermosetting matrix at 180 °С for 3 h is accompanied with removal of 67 wt.% pore-forming agent and the decreasing of material density by 32 %. The pyrolysis of cured compositions is accompanied with mass loss and chemical shrinkage. The maxima of mass loss rate take place at temperatures, which are 20-40 °C higher, than for the maxima of shrinkage rate. The regularities observed lead to the step changes of density with local increasing due to shrinkage prevailing and local decreasing due to mass loss prevailing. The final density of the pyrolysed material is 2-5 % higher than the density of initial uncured composition. The thermokinetics methods were used to propose time-temperature regime, which minimizes the local decreasing a density due to mass loss and can be used to formation of samples with uniform pore distribution. It was suggested that to obtain the matrix with developed pore structure form of the composition investigated, the reinforcing skeleton, which does not shrink at the temperatures studied, but has sufficient adhesion with pyrolysis products, should be used.

Fabrication of Continuous-SiC-Fiber-Reinforced SiAlON-Based Ceramic Composites by Reactive Melt Infiltration

2004 ◽  
Vol 84 (9) ◽  
pp. 1945-1951 ◽  
Author(s):  
Satoshi Kitaoka ◽  
Naoki Kawashima ◽  
Toshiyuki Suzuki ◽  
Yuji Sugita ◽  
Nobuo Shinohara ◽  
...  
Keyword(s):  
Ceramic Composites ◽  
Fiber Reinforced ◽  
Sic Fiber ◽  
Melt Infiltration ◽  
Reactive Melt Infiltration ◽  
Reactive Melt
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