Micro and nanoarchitectonics of ZrC filler with size effects on densification and ablative mechanism of C/C-SiC-ZrC composites

To shorten the manufacturing process and enhance the ZrC content, C/C-SiC-ZrC composites were prepared using the nano-filler slurry infiltration method in combination with precursor infiltration and pyrolysis method. The effect of ZrC filler sizes on densification, microstructure, and properties of composites was studied. Results revealed that the ZrC content and density of the C/C-SiC-ZrC composites are inversely correlated to the filler size. The composites with nano-fillers reach the highest density of 2.67 g cm⁻³ as well as the lowest open porosity of 1.21%. After being ablated under oxyacetylene flame for 60 s, the composites with nano-fillers owns the lowest linear ablation rate and surface temperature, with 10 μms⁻¹ and 2700 °C. Due to the highest ZrC content and best film-forming ability of nano-fillers, ZrO₂ outer layer with the densest structure can provide an enhanced protective effect, and the thickness of the oxide layer decreases from 509 to 264 μm as compared with micron fillers. Therefore, the oxidation damage of the composites is reduced, and the thickness of the SiC depletion layer decreases simultaneously. The above results further demonstrate that introducing ZrC nano-filler to the C/C-SiC-ZrC composites can considerably improve their ablative properties at 2700 °C.