Synthesis,characterization, and ceramization of a carbon-rich SiCw-ZrC-ZrB2 preceramic polymer precursor

A precursor (PBSZ) for SiC_w-ZrC-ZrB₂ hybrid powder was synthesized by chemical reaction of phenol, paraformaldehyde, zirconium oxychloride, boric acid and tetraethylorthosilicate. Results show that zirconium, silicon and boron atoms have been successfully introduced into the branched structure. Decomposition of PBSZ is completed at 800 °C, and it gives amorphous carbon, SiO₂, B₂O₃ and ZrO₂ with a yield of 38% at 1200 °C. During the pyrolysis process, ZrB₂ and SiC form at about 1500 °C, followed by the appearance of ZrC when the amount of B₂O₃ is limited. Highly crystallized ZrB₂–ZrC–C powder with ZrB₂ and ZrC grains evenly distributed in the carbon matrix together with randomly distributed SiC whiskers are obtained after heat-treated at 1800 °C. Further heated at 1900 °C, ZrB₂ and ZrC grains grow from 200 to 500 nm, while SiC whiskers show a much smaller diameter size and tend to grow on the ZrB₂–ZrC–C block surface. The morphology difference is caused by the larger gas supersaturation and accommodation coefficient of the pore channels on the block surface. In addition, defects of the carbon matrix are cumulated to the highest at 1500 °C and the structure-ordered carbon is obtained after heat treated at 1900 °C.