Fabrication, Characterization and Suitability of 3D Non-woven Needle-Punched Preform C_f–SiC_m Composites for Ultra-High Temperature Applications

In the present study, 3D non-woven needle-punched preform (NPP) C_f–SiC_m composite with 7.5 pct volume fraction of carbon fiber is prepared via liquid silicon infiltration technique and characterized for microstructure, phase formation and mechanical behaviors. Additionally, the composite is subjected to plasma arc jet tests for evaluation of ablation resistance under ultra-high temperature oxidation environment. The dense composite (density ~ 2.5 to 2.6 g/cm³) contains β-SiC phase due to the reaction between infiltrated molten silicon and carbon matrix surrounding the carbon fibers. The resultant C_f–SiC_m composite shows high hardness and high abrasion resistance due to a higher proportion of hard SiC matrix as well as exhibits various toughening mechanisms from the carbon fiber reinforcement causing a delay in fracture. It also contains excellent resistance to thermal shock and thermo-oxidative erosion resistance during plasma arc jet ablation test without any visible crack or damage on the exposed surface.