Lightweight multiscale hybrid carbon-quartz fiber fabric reinforced phenolic-silica aerogel nanocomposite for high temperature thermal protection

Multiscale hybrid method is reported to enhance thermal ablative and insulative properties of lightweight ablative materials in high temperature oxidation extreme environment. A novel lightweight hybrid carbon-quartz fiber fabric reinforced phenolic-silica (C-QF/PSi) aerogel nanocomposite was fabricated through impregnation using C-QF hybrid needled felt as three-dimensional reinforcement and PSi hybrid aerogel as matrix. The prepared aerogel nanocomposite perfectly inherits their nanoporous microstructure and fascinating properties, resulting in remarkable high compressive strength (5.96–17.01 MPa), low thermal conductivity (~0.112 W/(mK)). In particular, good thermal ablative and insulative properties in oxy-acetylene oxidizing flame (linear ablation rate as low as 0.017 mm/s and internal temperature peaks below 100 °C at 80 mm in-depth position when the surface temperature exceeds 2000 °C). From mentioned above, this lightweight composite presents huge application prospects in thermal protection and heat insulation field, especially in aerospace industry.