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From Fragile Insulation to Self-Supporting Shield: Porous SiC/B4C Coated Carbon Felts for Self-Healing Long-Life Thermal Protection
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DOI：10.1016/j.ceramint.2026.08.139.png)
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Abstract
En 中文
Carbon fiber soft felt is widely used in high-temperature thermal management systems due to its exceptionally low thermal conductivity. However, its inherent low mechanical strength and poor oxidation resistance lead to rapid degradation under high-temperature oxidative conditions, severely limiting its service reliability. To address this challenge, this study proposes a "rigid shell-flexible core" biphasic structure architecture. A porous SiC/B4C ceramic coating is constructed on the carbon fiber felt surface via in-situ foaming combined with carbothermal reduction, forming a deeply mechanically interlocked interface between the rigid ceramic shell and the compliant fiber network. The resulting composite achieves a compressive strength of 5.92 MPa, representing an increase of over 500 times compared to the pristine felt, thereby enabling self-supporting structural capability. Under high-temperature oxidative conditions, the in-situ formation of a B2O3–SiO2 glass phase within the ceramic shell enables self-healing behavior, which seals surface pores and suppresses oxygen diffusion toward the internal fiber network. Additionally, the hierarchical porous structure introduces enhanced phonon scattering and multiphase interfacial thermal resistance, allowing the composite to maintain an ultra-low thermal conductivity of 0.21 W·m-1·K-1 even at 1550 °C. This work provides a novel structural design paradigm to address the long-standing trade-off between mechanical robustness and thermal insulation in thermal protection materials, with promising implications for applications in aerospace, semiconductor manufacturing, and other high-temperature sectors.
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