A universal strategy towards the fabrication of ultra-high temperature ceramic matrix composites with outstanding mechanical properties and ablation resistance

Materials with both excellent mechanical properties and good ablation resistance are urgently needed for the applications of thermal protection system in extreme high temperature oxidizing environments. However, owing to the lack of efficient fabrication processes, the existing materials suffer from either insufficient mechanical properties or poor ablation resistance. Herein, we report a novel solid–liquid combination fabrication strategy that successfully achieves the efficient incorporation of ultra-high temperature ceramics into 3D continuous carbon fiber performs as well as rapid densification. The relative density of the green body approaches the cubic close packing of spherical particles. Using C_f/ZrB₂–SiC as an example, the as-prepared composite exhibits outstanding mechanical properties with a flexural strength surpasses 600 MPa and an unprecedented work of fracture of 11,851 ± 838 J/m², which is two orders of magnitude higher than that of the currently reported monolithic ultra-high temperature ceramics. Moreover, the high ZrB₂ content endows the composites with excellent ablation resistance and is thus capable of maintaining long-term non-ablative conditions at 2500 °C. The strategy possesses remarkable universality and high design flexibility, providing a time-saving and cost-effective universal strategy for the on-demand design and fabrication of high-performance ceramic, carbon, metal, and polymer matrix composites.