Lightweight and resilient SiOC/SiC foam with efficient electromagnetic wave absorption and high-temperature stability

Integrating multiple functions such as high electromagnetic (EM) wave absorption, thermal insulation, and resilience into one material is critical, especially for applications in harsh environment. SiC ceramic has received considerable attention as high-temperature wave absorber, but its applications are limited by common wave absorption performance and brittleness of ceramics. Here by incorporating SiO₂ with SiC in a unique three-dimensional network structure, SiOC/SiC foam consisting of abundant SiOC thin flakes interconnected by numerous long interweaving SiC nanowires have been prepared. The foam shows high EM wave absorption with minimum reflection loss of −30.23 dB, broad effective absorption bandwidth of 5.4 GHz, and a nearly complete compressive resilience from 10% strain. Besides, the foam displays high-temperature resistance up to 1400°C in air and good thermal insulation performance. Such multifunctional material is promising for applications in advanced aerospace industry under extreme conditions.     

High-temperature oxidation induced layering process for Si–C–B–N ceramic fibers with SiC nanograins

High-temperature oxidation resistance is important for Si–C–B–N ceramic fibers when reinforcing ceramic matrix composites with superior reliability and faulting tolerance. At present, few studies have investigated on the high-temperature oxidation behavior of Si–C–B–N fibers, limiting their further applications. In this work, we analyzed the high-temperature oxidation process of Si–C–B–N ceramic fibers with SiC nanograins (SiBCN-SiCn fibers) at 1000–1500 °C in air. SiBCN-SiCn fibers stated to be oxidized at 1000 °C, with the formation of thin oxide layer. After oxidizing at 1300 °C, obvious oxide layer that mainly consisted of amorphous SiO₂ could be detected. Further oxidizing at 1500 °C caused the thickness increment of oxide layer, which could inhibit the oxidation products (CO, N₂) to release away from the fibers. The remained CO and N₂ may react with SiC nanograins to form SiO₂ and graphite-like g-C₃N₄, causing the formation of additional transition layer. Our finding may support useful information for the applications of SiBCN-SiCn fibers under harsh environment.     

Preparation and mechanical behaviors of SiOC-modified carbon-bonded carbon fiber composite with in-situ growth of three-dimensional SiC nanowires

Carbon-bonded carbon fiber (CBCF) composites are novel and important high-temperature insulation materials owing to their light weight, low thermal conductivity and high fracture tolerance. To further improve the mechanical property of CBCF composite, we propose a three-dimensional (3D) SiC nanowires structure, which is in situ grown on a CBCF matrix via directly annealing silicon oxycarbide (SiOC) ceramic precursor. The synthesized multiscale reinforcements including microscale SiOC ceramics and nanoscale SiC nanowires are mainly attributed to the initial phase separation of SiOC phase and subsequent solid-phase reaction of SiO and C phases. Compared to SiOC/CBCF composite, the resulting 3D SiC nanowires/SiOC/CBCF hybrid structure exhibited high flexural/tensile strength and fractured strain due to the pull-out and bridging behavior of SiC nanowires. This one-step process supplied a feasible way to synthesize 3D SiC nanowires to reinforce and toughen SiOC-modified CBCF composite.     

Photoluminescence property of inexpensive flexible SiC nanowires membrane by electrospinning and carbothermal reduction

Silicon carbide nanowire (SiC NW), as a typical wide band gap semiconductor was used as light-emitting materials and devices in high-temperature and harsh environments due to its excellent properties. In this paper, flexible ultra-long SiC NWs membrane was successfully synthesized by electrospinning and subsequently high-temperature sintering using phenolic resin and silica sol as precursors. Results of system characterization reveal that SiC NWs possess a smooth and uniform surface with diameter distribution mainly between 50-300 nm and a length of more than tens of micrometers, forming a network structure. The growth mechanism of synthesized nanowires was mainly carbothermal reduction in situ and was accompanied by vapor-solid (V-S) reaction. The present work provides a simple and cost-effective way for controllable fabrication of SiC NWs membrane. The photoluminescence spectrum of SiC NWs membrane emerged a clear blue shift, indicating a potential application in optoelectronic devices and discussed the potential applications of SiC NWs membrane in other fields.     

Flexible ultrafine nearly stoichiometric polycrystalline SiC fibers with excellent oxidation resistance and superior thermal stability up to 1900 °C

Flexible ultrafine SiC fibers with superior high-temperature stability and excellent oxidation resistance are regarded as one of the most promising materials for high-temperature applications. However, excess oxygen and carbon in the ultrafine SiC fibers limit their thermal stability due to decomposition of the SiC_xO_y phase. In the present work, flexible ultrafine nearly stoichiometric polycrystalline SiC fibers were fabricated by combining the electrospinning technique and polymer-derived ceramic method. The ultrafine SiC fibers exhibited superior high-temperature stability and oxidation resistance. The retention rates of tensile strength were 90.0 %, 94.2 % and 86.4 % after heat treatment in argon at 1800 °C, 1900 °C and 2000 °C, respectively. TG results of the fibers showed little weight loss of only 1.52 % at 1900 °C in Ar and the weight gain of only 4.1 % up to 1500 °C in air. Such improved thermal stability was achieved through sintering at high temperature for elimination of excess oxygen and carbon with Al doped as the sintering aid to restrain the grain coarsening. The ultrafine SiC fibers still exhibited excellent flexibility without obvious damage when they were heated by the butane blowtorch flame of about 1100 °C in air. Furthermore, the infrared thermography illustrated that the ultrafine SiC fiber membrane also had good thermal insulation performance. The outstanding mechanical properties and thermal stability of ultrafine SiC fibers suggest their potential applications at the high temperature and harsh environment.     

Multifunctional ultralight,recoverable, piezoresistive,and super thermal insulating SiC nanowire sponges

Ultralight three-dimensional (3D) architectured silicon carbide (SiC) nanowire sponges with integrated properties of recoverable compressibility, outstanding high-temperature thermal and chemical stability, and fire-retardance have been actively pursued in recent years. However, efficient construction of SiC nanowire sponges with well-controlled overall shapes and distribution of SiC nanowires remains challenging. Herein, by coupling the electrospinning technique and carbothermal reduction process, we have developed a new fabrication process for highly porous and free-standing 3D SiC nanowire (SiCNW) sponges with closely attached nanowires through thermal treatment of stacked electrospun PAN/SiO₂ nanofiber membranes. The resulting SiCNW sponges possess ultralow density (∼29 mg cm⁻³), excellent compressive recoverability from large compressive deformation (up to 40% strain), and fatigue resistance, which endow them with excellent piezoresistive sensing capability under a variety of complex conditions. Furthermore, the sponges display superb thermal insulation (thermal conductivity of 24 mW m⁻¹K⁻¹) and fire-retardance. We believe that the present process provides technical clues for the development of other multifunctional ceramic sponges, and that further development of these ultralight multifunctional ceramic sponges offers potential for the design of advanced components for application in harsh engineering environments.     

Tensile creep properties and damage mechanisms of 2D-woven C/HfC–SiC composites in high temperature

2D-C/HfC–SiC composites were prepared by a combination of precursor infiltration and pyrolysis (PIP) and chemical vapor infiltration (CVI). Creep tests were performed at 1100°C in air under different stress conditions. Unlike most, C/SiC and SiC/SiC ceramic matrix composites only underwent primary and secondary creep stages, and the C/HfC–SiC composites underwent tertiary creep stage in the creep process. The reason was that the mechanical properties of C/HfC–SiC materials prepared by PIP + CVI methods were different from those prepared by traditional methods. The microscopic morphological analysis of the sample fracture showed that the oxidation products SiO₂ and Hf–Si–O glass phases of the HfC–SiC matrix played a crack filling role in the sample during creep. In turn, it provided effective protection to the internal fibers of the sample. The creep failure of C/HfC–SiC composites in a high-temperature oxidizing atmosphere was caused by the oxidation of the fibers. The total creep process was dominated by the oxidation of carbon fibers. It is noteworthy that there was the generation of Hf_xSi_yO_z nanowires in the samples after high-temperature creep. The analysis of the experimental data showed that the creep stress had a linear negative correlation with the creep life.     

SiC Particulate-Reinforced Si–C–N—Highly Oxidation Resistant Composites at 1500°C in Air

The thermal stability and high-temperature strength of SiC filler/Si–C–N matrix particulate-reinforced ceramic (PRC) composites were investigated. The PRC retained 115% of the room temperature strength at 1500°C in air because of the crack-healing behavior. The thickness of SiO₂ formed on the PRC was 3 μm after an oxidation at 1500°C for 100 h in air. The strength of the PRC did not strongly decrease after the prolonged oxidation for 100 h. The SiC/Si–C–N PRC are a promising candidate for the applications at extremely high temperatures in air.     

Green synthesis of blue-green photoluminescent β-SiC nanowires with core-shell structure using coconut shell as carbon source

This work proposes a green method for synthesizing SiC nanowires (NWs) via the chemical vapor deposition (CVD) technique using coconut shell and silicon as raw materials. Using coconut shell as carbon source decreases the synthesis temperature of SiC. A large number of core-shell SiC NWs were obtained after firing at 1200 °C, a thin SiO₂ layer is distributed on the outer shell of SiC NWs. The synthesized SiC NWs grow along the [111] direction, up to dozens of micrometers in length and diameters of 10–75 nm. However, the chain-bead structure of SiC NWs is formed after firing at 1400 °C due to the SiO₂ bead embedded in SiC NWs. The synthesized core-shell SiC NWs fired at 1200 °C emit strong violet-blue light, which has good application prospects in optoelectronic devices.     

SiOC modified carbon-bonded carbon fiber composite with SiC nanowires enhanced interfibrous junctions

Carbon-bonded carbon fiber (CBCF) composites are promising lightweight and high efficient thermal insulators to be applied in aerospace area, but their practical applications are usually restricted by the low mechanical performance and poor oxidation resistance. To overcome these drawbacks, many efforts have been made in the fabrication of ceramic coated CBCF composites. However, the densities of these modified composites are usually very high, which would result in the reduction in their thermal insulation performance. Herein, we prepared a CBCF composite with SiC nanowires enhanced interfibrous junctions and SiOC ceramic coated carbon fibers (SiCNWs-SiOC-CBCF). Similar to CBCF, the SiCNWs-SiOC-CBCF exhibits a low density of 0.35 g/cm³ and an anisotropic and highly porous architecture. The SiCNWs-SiOC-CBCF possesses a compressive strength of 3.8 MPa and a compression modulus of 195.7 MPa in the X (or Y) direction, ~26.7% and 150% higher than those of CBCF respectively. It can also suffer from an isothermal treatment in air at 900°C for 120 minutes. The combination of these properties makes the SiCNWs-SiOC-CBCF a good candidate for thermal insulator to be applied in extreme conditions.     

Effects of Si3N4 and WC on the oxidation resistance of ZrB2/SiC ceramic tool materials

ZrB₂/SiC, ZrB₂/SiC/Si₃N₄ and ZrB₂/SiC/WC ceramic tool materials were prepared by spark plasma sintering technology, and their oxidation resistance was tested at different oxidation temperatures. When the oxidation temperature is 1300 °C, the oxide layer thickness, oxidation weight gain and flexural strength of ZrB₂/SiC/Si₃N₄ ceramic tool material after oxidation are 8.476 μm, 1.436 mg cm^?2 and 891.0 MPa, respectively. Compared with ZrB₂/SiC ceramic tool materials, the oxide layer thickness and oxidation weight gain are reduced by 8.2% and 11.8%, respectively, and the flexural strength after oxidation is increased by 116.1%. However, the addition of WC significantly reduces the oxidation resistance of the ceramic tool material. A dense oxide film is formed on the surface of ZrB₂/SiC/Si₃N₄ ceramic tool material during oxidation, which effectively prevents oxygen from entering the inside of the material, thereby improving the oxidation resistance of the ceramic tool material.     

Preparation and ablation properties of SiC nanowire-reinforced ZrC–SiC coating-matrix integrated C/C composites

A modification of the precursor infiltration pyrolysis (PIP) method was explored to prepare the integrated doped ceramic matrix and coating by the added SiC nanowires layer and shape-stabilization process. The epitaxial layer of SiC nanowires provided surficial attachments for the precursor. And the shape-stabilization process aggregated loose ceramic particles into a coating. Then the SiC nanowire-reinforced ZrC–SiC coating-matrix integrated C/C (S/SZ-CZ/C) composite was simply prepared by the modified PIP method. The bonding strength between the coating and matrix of the S/SZ-CZ/C composite was improved. Through the ablation test, the mass and linear ablation rate of the S/SZ-CZ/C composite were 0.46 mg/s and 0.67 μm/s, which were 60.34 % and 74.91 % lower than those of the SiC nanowire-reinforced C/C–ZrC (S/CZ/C) composite, respectively. The integration of the coating and matrix enabled the formation of a continuous oxide layer of molten SiO₂ and ZrO₂ in the ablation process, which helped to block the oxygen and heat during the ablation test. Thus the ablation resistance of the materials was systematically and effectively improved.     

Synthesis of SiC nanowires by a simple chemical vapour deposition route in the presence of ZrB2

The SiC nanowires (NWs) were fabricated by a simple chemical vapour deposition (CVD) method at high temperature using Si, phenolic resin, and ZrB₂ powder. The morphologies of the fabricated SiC NWs included SiC/SiO₂ chain-beads and straight wires with core-shell structures. The fabricated SiC NWs were micrometre-to-millimetre in length, with chains 100–300 nm in diameter and beads with diameters of less than 1 μm. The core-shell-structured SiC NWs consisted of crystalline SiC cores and thin amorphous SiO₂ shells. SiC crystals grew in the [111] direction governed by a vapour-solid (VS) mechanism. The added ZrB₂ promotes the generation of gaseous species at higher gas pressures, which contributes to the formation of SiC NWs by CVD. The fabricated SiC NWs exhibited good photoluminescence properties due to many stacking faults and the presence of amorphous SiO₂.     

Self‐Generating High‐Temperature Oxidation‐Resistant Glass‐Ceramic Coatings for C–C Composites Using UHTCs

Carbon–carbon (C–C) composites are ideal for use as aerospace vehicle structural materials; however, they lack high‐temperature oxidation resistance requiring environmental barrier coatings for application. Ultra high‐temperature ceramics (UHTCs) form oxides that inhibit oxygen diffusion at high temperature are candidate thermal protection system materials at temperatures >1600°C. Oxidation protection for C–C composites can be achieved by duplicating the self‐generating oxide chemistry of bulk UHTCs formed by a “composite effect” upon oxidation of ZrB₂–SiC composite fillers. Dynamic Nonequilibrium Thermogravimetric Analysis (DNE‐TGA) is used to evaluate oxidation in situ mass changes, isothermally at 1600°C. Pure SiC‐based fillers are ineffective at protecting C–C from oxidation, whereas ZrB₂–SiC filled C–C composites retain up to 90% initial mass. B₂O₃ in SiO₂ scale reduces initial viscosity of self‐generating coating, allowing oxide layer to spread across C–C surface, forming a protective oxide layer. Formation of a ZrO₂–SiO₂ glass‐ceramic coating on C–C composite is believed to be responsible for enhanced oxidation protection. The glass‐ceramic coating compares to bulk monolithic ZrB₂–SiC ceramic oxide scale formed during DNE‐TGA where a comparable glass‐ceramic chemistry and surface layer forms, limiting oxygen diffusion.     

Multifunctional SiC/C hybrid fabric applicable for extreme environment ranging from liquid nitrogen temperature to 1000° C

Creating multifunctional materials that can serve in extreme environments is of critical importance but also a formidable challenge. Herein, we present a simple technique that combines carbothermic reduction and organic template carbonization to produce multifunctional SiC/C hybrid fabrics from inexpensive cotton mats. The obtained fabrics display high resilience to high/low temperature, anti-oxidation, and chemical assault is exhibited. Additionally, the fabric's ultralow thermal conductivity results in superior thermal insulation performance. Notably, these in situ-generated SiC nanowires considerably improve the ductility of the ceramic fabric. The compression strength and the breaking elongation increased by 39% and 2.6%, respectively, as compared to the SiC fabric without grown nanowires. When employed as an electromagnetic interference shielding material, it exhibits an excellent EMI shielding capability with a SE value of 40 dB. This research advances not just the usability of flexible ceramic fabrics in severe environments, but also the creation of fine structures in ceramic materials.     

Synthesis and microwave absorption properties of SiC nanowires reinforced SiOC ceramic

Silicon carbide nanowires (SiC NWs) reinforced SiOC ceramics were fabricated through in situ growth of SiC NWs in SiOC ceramics by pyrolysis of polysiloxane. SiC NWs were in situ formed by the addition of ferrocene, the content of SiC NWs increased with the increases of annealing temperature and ferrocene content. Due to the formation of SiC NWs in the inter-particle pores of SiOC ceramics, the SiOC particles were bridged by SiC NWs, which led to the increase of electrical conductivity. With the increase of SiC NWs content, the real permittivity and the imaginary permittivity increased from 3.63 and 0.14 to 10.72 and 12.17, respectively, and the minimum reflection coefficient decreased from −1.22 dB to −20.01 dB, demonstrating the SiOC ceramics with SiC NWs had a superior microwave-absorbing ability.     

Oxidation of SiC/BN/SiC ceramic matrix composites in dry and wet oxygen at intermediate temperatures

The oxidation behavior of SiC/BN/SiC ceramic matrix composites (CMCs) was evaluated from 400° to 800 °C in 100% O₂ and 50% H₂O/50% O₂ gas mixtures. Thermogravimetric analysis (TGA) was utilized to measure weight change during controlled environment exposures at elevated temperatures for 1 and 50 hours. Oxidized CMCs and their oxides were studied post-exposure with scanning electron microscopy and energy dispersive spectroscopy. The oxidation onset and composition transition temperatures were evaluated. Key observations include oxide composition, oxide wetting, oxygen solubility in Hi-Nicalon SiC fibers and BN fiber coating oxidation and volatility behavior as a function of temperature. Degradation in wet environments at 600 °C was most extensive due to the formation of a non-wetting, non-protective surface oxide, allowing oxidant access to the BN fiber coatings followed by oxidation and volatilization. Implications of the CMC oxidation behavior are discussed for CMCs in service.     

Synthesis and thermophysical properties of ATa2O6 (A = Co,Ni, Mg,Ca) tantalates with robust CMAS resistance

A new family of ceramic environmental/thermal barrier coating (E/TBC) materials, that is, ATa₂O₆ (A = Co, Ni, Mg, Ca), for high-temperature applications, are investigated and reported in this study. We focus on the synthesis and features of crystal structures, and on the mechanical and high-temperature properties. ATa₂O₆ oxides have an extraordinary phase stability (up to 1300°C), and their thermal expansion coefficients (6.2–7.3 × 10⁻⁶ K⁻¹) match those of SiC fiber-enhanced SiC ceramic matrix composites (3–7 × 10⁻⁶ K⁻¹). Their low thermal conductivities (min: 1.15 W·m⁻¹·K⁻¹) root in the slow phonon spreading speed and fierce phonon-phonon scattering process, and they will provide exceptional thermal insulation. Moreover, their hardness (5.6–8.8 GPa), toughness (1.4–1.9 MPa·m^1/2), and moduli (100–210 GPa) have good comparability with current E/TBCs. We propose the 33CaO-9MgO-13AlO_1.5-45SiO₂ (CMAS) corrosion mechanisms of ATa₂O₆ ceramics, and their robust CMAS resistance relies on the phase stability of CaTa₂O₆ oxides. The excellent high-temperature properties ensure that ATa₂O₆ can be used as E/TBCs to provide thermal insulation and CMAS corrosion protection.     

Synthesis of SiBNC-Al ceramics with different aluminum contents via polymer-derived method

This study reports the synthesis of three types of aluminium (Al)-modified polyborosilazane ceramic precursors (PBSAZ) from C₈H₁₉Al/HSiCl₃/HMDZ/BCl₃ and their thermal conversion to SiBNC-Al ceramics at 1000°C. FT-IR, nuclear magnetic resonance (NMR), X-ray photoelectron spectroscopy (XPS), and thermogravimetric analysis (TGA) are used to characterize the structures and properties of the PBSAZ. PBSAZ is found to be built up of the Si─N─B framework, with Al successfully introduced into the ceramic network structures. The ceramic yield is 63.5 wt.% for the Al-poor polymers (PBSAZ-5) and 65.1 wt.% for the Al-rich polymers (PBSAZ-1). The high-temperature cracking behavior and the crystal phase structures of the ceramics were characterized by XRD and Raman, which revealed that SiBNC-Al ceramics contained Si₄N₃, SiC, and AlN (+SiC) crystals after heat treatment at 1600°C. The oxidation behavior of SiBNC and SiBNC-Al ceramics at 1500°C shows that the introduction of Al improves the quality of the oxide layer, effectively suppresses the oxide layer cracking phenomenon, and reduces gas bubble generation.     

Improved mechanical strength and thermal resistance of porous SiC ceramics with gradient pore sizes

Thermal insulation applications of porous SiC ceramics require low thermal conductivity and high mechanical strength. However, low thermal conductivity and high mechanical strength possess a trade-off relationship, because improving the mechanical strength requires decreasing the porosity, which increases the thermal conductivity. In this study, we established a new strategy for improving both the mechanical strengths and thermal resistances of porous SiC ceramics with micron-sized pores by applying a double-layer coating with successively decreasing pore sizes (submicron- and nano-sized pores). This resulted in a unique gradient pore structure. The double-layer coating increased the flexural strengths and decreased the thermal conductivities of the porous SiC ceramics by 24–70 % and 29–49 % depending on the porosity (48–62 %), improving both their mechanical strengths and thermal resistances. This strategy may be applicable to other porous ceramics for thermal insulation applications.