Novel class of precursor-derived Zr–La–B–C(O) based ceramics containing nano-crystalline ultra-high temperature phases stable beyond 1600 °C

In this work, a novel ultra-high temperature resistant precursor-derived ceramic containing Zr, La, B, and C was synthesized through precursor modification of phenol formaldehyde resin. The thermal stability and resistance to crystallization of the ceramic at a temperature of 1600 °C was investigated and was found to be profoundly influenced by the boron content in the starting precursors. The ceramics remained amorphous at 1600 °C for 2 h in argon and upon sustained heat-treatment for up to 16 h resulted in nano-crystalline ultra-high temperature phases such as ZrB₂, ZrC, LaB₆ and La₂Zr₂O₇. Thermodynamic equilibrium phase calculations show that even longer durations of heat treatment may be required to achieve thermodynamic equilibrium. High-resolution transmission electron microscopy revealed encapsulation of nanocrystals (<5 nm) in an amorphous matrix surrounded by turbostratic layers of carbon inhibiting its growth. Spectrochemical techniques confirmed the presence of boron substituted carbon in the amorphous matrix of the ceramic. The unique nature of the amorphous matrix lends the ceramic resistance to crystallization and chemical degradation that can surpass the likes of classical silicon-based precursor-derived ceramics.