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<p>Enhancing oxidation resistance of carbon fiber–reinforced carbon (C/C) composites remains essential for service in extreme environments. Conventional silicon carbide (SiC) surface coatings help, but thermal-expansion mismatch can trigger reliability issues. We introduce an interface-stabilization strategy using vertically aligned one-dimensional (1D) glassy-carbon rod arrays to mitigate high-temperature oxidation damage. The oxidation-protective C/SiC composite film (OPCF) was fabricated by electrostatic spray deposition of carbon rod arrays, carbonization of phenol–formaldehyde resin, and formation of a surrounding SiC layer via polymer impregnation and pyrolysis. This interfacial architecture lowers thermal stress between the C/C substrate and the SiC coating. Finite-element analysis confirms substantial stress reduction. Under severe conditions, the OPCF-processed C/C composites exhibited exceptional oxidation resistance, showing &lt; 5% weight loss and preserved flexural integrity. These results demonstrate that embedding 1D carbon rod arrays provides an effective route to stabilize C/C–SiC interfaces for high-temperature applications.</p>

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Interface stabilization for C/C-layered composites by placing 1-D carbon arrays

  • 期刊论文

  • 发表日期：

    2025年11月17日

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  • Baek Hyun Kim,
  • Hyunah Kim,
  • Do-Kyun Kwon

摘要

Enhancing oxidation resistance of carbon fiber–reinforced carbon (C/C) composites remains essential for service in extreme environments. Conventional silicon carbide (SiC) surface coatings help, but thermal-expansion mismatch can trigger reliability issues. We introduce an interface-stabilization strategy using vertically aligned one-dimensional (1D) glassy-carbon rod arrays to mitigate high-temperature oxidation damage. The oxidation-protective C/SiC composite film (OPCF) was fabricated by electrostatic spray deposition of carbon rod arrays, carbonization of phenol–formaldehyde resin, and formation of a surrounding SiC layer via polymer impregnation and pyrolysis. This interfacial architecture lowers thermal stress between the C/C substrate and the SiC coating. Finite-element analysis confirms substantial stress reduction. Under severe conditions, the OPCF-processed C/C composites exhibited exceptional oxidation resistance, showing < 5% weight loss and preserved flexural integrity. These results demonstrate that embedding 1D carbon rod arrays provides an effective route to stabilize C/C–SiC interfaces for high-temperature applications.