Ablation characteristics of mosaic structure ZrC-SiC coatings on low-density, porous C/C composites

doi:10.1016/j.jmst.2019.08.004

Abstract

Abstract:

Mosaic structure ZrC-SiC coatings were fabricated on low-density, porous C/C composites via thermal evaporation and an in-situ method. ZrC was packed in a typical lamellar mode, and the mosaic structure was formed by the deposition of Zr and Si atoms on the shallow surface of the porous C/C composites. Ablation analysis showed that the defects in the coatings originate from the boundary between the ZrC and holes created by the consumption of SiC at 2500?°C. After ablation for 200?s at 3000?°C, a dense ZrO₂ layer formed on the coating surface, and the defects were sealed owing to the continuous supply of ablative components. The mass and line ablation rates of the ZrC-SiC coatings were -0.46?±?0.15?mg?cm^-2·s^-1 and -1.00± 0.04?μm?s^-1, respectively.

Key words: ZrC, SiC, Coating, Mosaic structure, Porous C/C composites, Ablation

Yonglong Xu, Wei Sun, Xiang Xiong, Fuqun Liu, Xingang Luan. Ablation characteristics of mosaic structure ZrC-SiC coatings on low-density, porous C/C composites[J]. J. Mater. Sci. Technol., 2019, 35(12): 2785-2798.

Figures/Tables 16

Fig. 1. X-ray diffraction patterns of ZrC-SiC coatings.

Fig. 2. Surface morphology of the CL coating: (a) surface morphologies of ZrC and SiC, (b) ZrC groove, (c) and (d) zigzag-like laminated ZrC phase.

Fig. 3. Surface morphology of the CH coating: (a) surface morphologies of ZrC and SiC, (b) ZrC groove, (c) laminated ZrC phase, (d) ZrC packed in the terrace-ledge-kink and spiral growth models, (e) and (g) the Zr, C, and Si element distributions shown in Fig. 3(b).

Table 1 Electron probe microanalysis results of CH and CL coatings.

Position	Element (at.%)
Position	Zr	Si	C
1	43.9804	0.0631	55.9564
2	42.9753	0.1452	56.8794
3	35.7749	0.0331	64.1919
4	33.9895	0.1240	65.8885
5	48.5536	0.0753	51.3711
6	44.6917	0.0842	55.2241

Fig. 4. Cross-sectional morphologies of ZrC-SiC coatings: (a) cross-sectional morphology of coating CH, (b) morphology of the outer ZrC-SiC mixed layer and the SiC-rich transition layer in the CH coating, (c) SiC-C boundary, (d) C-SiC-ZrC-SiC-C boundary in the infiltration layer (depth of approximately 500?μm from the coating surface), (e) cross-sectional morphology of the CL coating, (f) morphology of the outer ZrC-SiC mixed layer and SiC-rich transition layer in the CL coating, (g) C-SiC-ZrC-SiC-C boundary in the infiltration layer of the CL coating (depth of approximately 1000?μm from the coating surface).

Fig. 5. Raman spectra and graphitization degree of the C/C matrix near the CH and CL coatings: (a) Raman spectra of the carbon matrix adjacent to the SiC inner layer at an interval of 50?nm, and (b) graphitization degree of the carbon matrix shown in Fig. 5(a).

Table 2 Mass and linear ablation rates of ZrC-SiC coatings.

Sample	Ablation temperature (°C)	Ablation time (s)	Mass ablation rate (mg·cm^-2·s^-1)	Linear ablation rate (μm·s^-1)
CH	2500	60	0.03?±?0.01	-0.16?±?0.02
CL	2500	60	0.04?±?0.01	-0.14?±?0.03
CL	3000	30	0.03?±?0.01	-0.13?±?0.02
CL	3000	60	-0.10?±?0.02	-1.33?±?0.04
CL	3000	200	-0.46?±?0.15	-1.00?±?0.04

Fig. 6. X-ray diffraction patterns of the ZrC-SiC coatings after ablation.

Fig. 7. Morphologies of central ablation surface regions of the CH coating after 60?s of ablation at 2500?°C: (a) central ablation region, and (b) and (c) morphology of ZrO2 near the crack.

Fig. 8. Surface morphology of the CL coating after 60?s of ablation at 2500?°C: (a) central ablation region, (b) and (c) morphologies of ZrO2 near the SiO2 hole, and (d) and (e) transition region of the CL coating.

Fig. 9. Cross-sectional morphologies of the ZrC-SiC coatings: (a) and (b) cross-sectional morphologies of the CH coating, (c)-(e) cross-sectional morphologies of the CL coating.

Fig. 10. Structural evolution of ZrO2 on the surface of the CL coating after ablation: (a) and (b) ablation for 60?s at 2500?°C, (c) and (d) ablation for 30?s at 3000?°C, and (e) and (f) ablation for 60?s at 3000?°C.

Fig. 11. Cross-sectional morphology of the CL coating after ablation for 30?s at 3000?°C: (a) distributions of ZrC and SiC ceramics in the C/C matrix, (b) morphology of the outer ZrC-SiC mixed layer, (c) and (d) cross-sectional morphologies of SiO2 holes and distribution of micropores in ZrO2, and (e) C-SiC-ZrC-SiC-C boundary in the infiltration layer.

Fig. 12. Cross-sectional morphology of the CL coating after ablation for 200?s at 3000?°C: (a) and (b) cross-sectional morphologies of the CL coating, (c) dense ZrO2 layer on the coating surface, and (d) inner holes in the oxide layer.

Fig. 13. Surface morphology of the CL coating after 200?s of ablation at 3000?°C: (a) central ablation surface regions, (b) eroded carbon fibers exposed on the coating surface, and (c)-(e) dense ZrO2 surface with healing holes.

Fig. 14. Schematic of ablation model of the ZrC-SiC coatings: (a) structural evolution of ZrO2 during ablation, (b) formation of SiO2 holes, and (c) and (d) structural evolutions of the CL coating during long-duration ablation at 3000?°C.

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