A gradient composite coating to protect SiC-coated C/C composites against oxidation at mid and high temperature for long-life service

To improve the oxidation resistance of carbon/carbon (C/C) composites at mid and high temperature, a gradient composite coating was designed and prepared on SiC-coated C/C composites by in situ formed-SiO2 densifying the porous SiC-ZrSi2 pre-coating. SiO2 gradient distribution was conducive to inhibiting the cracking of the coating. A dual-layer structure with the outer dense layer and the inner microporous layer was formed in the coating during densifying. The dense layer had excellent oxygen diffusion resistance and the microporous layer alleviated CTE mismatch between SiC inner coating and dense layer. Moreover, ZrSiO4 particles inhibited crack propagation and stabilized SiO2 glass. Therefore, the coating can protect the C/C composites from oxidation at 1473 K, 1573 K and 1773 K for 810 h, 815 h and 901 h, respectively. The coated samples underwent 30 thermal cycles between room temperature and 1773 K without mass loss, exhibiting good thermal shock resistance.