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<p>Continuous carbon fiber-reinforced ZrB<sub>2</sub>-SiC ceramic matrix composites are promising thermal protection materials. Although injection-assisted vacuum impregnation (IVI) offers advantages such as shorter processing cycles, lower costs, and reduced fiber damage compared to conventional methods, phenolic/acetone-based IVI systems yield composites (designated as CPS) with limited ceramic contents. To address this, an aqueous slurry-based IVI approach was developed, producing composites designated as CHS. After a single IVI cycle, CHS achieved a ZrB<sub>2</sub> phase volume fraction of 25 vol.%, 47% higher than CPS, while reducing processing time by 49%. After chemical vapor infiltration, CVI-CHS composite exhibited a room-temperature compressive strength of 106.78±10.53 MPa, representing a 28% improvement over CVI-CPS. Crack propagation analysis revealed discontinuous zigzag patterns under compression, dominated by fiber bridging and pull-out energy dissipation mechanisms. Flexural results revealed both composites retain considerable strength (111.15±12.46 and 83.15±12.03 MPa) along with low flexural modulus (13.00±2.41 and 13.52±6.99 GPa) and high strain tolerance (1.32%±0.018% and 1.07%±0.34%). It is attributed to the anisotropy of fiber preforms and the elastic modulus mismatch among different phases, which hindered effective constraint of fibers by the matrix and, in turn, facilitated mitigation of stress concentration. Additionally, CVI-CPS demonstrated superior X-band electromagnetic interference (EMI) shielding (34–36 dB) compared to CVI-CHS (22–27 dB), resulting from synergistic effects between pyrolytic and deposited carbon in the matrix of the former. Both composites showed enhanced EMI shielding efficiency with increasing temperature up to 600°C. This eco-friendly aqueous IVI strategy enables high-performance, cost-effective thermal protection materials with higher ceramic loading and tunable multifunctional properties.</p>

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Rapid fabrication of Cf/ZrB2-SiC composites with multifunctional properties via aqueous injection-assisted vacuum impregnation

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • Chen Li,
  • Hailing Yang,
  • Ji Zou,
  • Jingjing Liu,
  • Weimin Wang,
  • Zhengyi Fu

摘要

Continuous carbon fiber-reinforced ZrB2-SiC ceramic matrix composites are promising thermal protection materials. Although injection-assisted vacuum impregnation (IVI) offers advantages such as shorter processing cycles, lower costs, and reduced fiber damage compared to conventional methods, phenolic/acetone-based IVI systems yield composites (designated as CPS) with limited ceramic contents. To address this, an aqueous slurry-based IVI approach was developed, producing composites designated as CHS. After a single IVI cycle, CHS achieved a ZrB2 phase volume fraction of 25 vol.%, 47% higher than CPS, while reducing processing time by 49%. After chemical vapor infiltration, CVI-CHS composite exhibited a room-temperature compressive strength of 106.78±10.53 MPa, representing a 28% improvement over CVI-CPS. Crack propagation analysis revealed discontinuous zigzag patterns under compression, dominated by fiber bridging and pull-out energy dissipation mechanisms. Flexural results revealed both composites retain considerable strength (111.15±12.46 and 83.15±12.03 MPa) along with low flexural modulus (13.00±2.41 and 13.52±6.99 GPa) and high strain tolerance (1.32%±0.018% and 1.07%±0.34%). It is attributed to the anisotropy of fiber preforms and the elastic modulus mismatch among different phases, which hindered effective constraint of fibers by the matrix and, in turn, facilitated mitigation of stress concentration. Additionally, CVI-CPS demonstrated superior X-band electromagnetic interference (EMI) shielding (34–36 dB) compared to CVI-CHS (22–27 dB), resulting from synergistic effects between pyrolytic and deposited carbon in the matrix of the former. Both composites showed enhanced EMI shielding efficiency with increasing temperature up to 600°C. This eco-friendly aqueous IVI strategy enables high-performance, cost-effective thermal protection materials with higher ceramic loading and tunable multifunctional properties.