The mechanical properties and ablation resistance of the C_f/ZrB₂-SiC-C composites fabricated using a cost-effective strategy

Carbon fiber reinforced ultra-high temperature ceramic matrix composites (C_f/UHTCMCs) are considered ideal materials for thermal protection components in hypersonic vehicles due to their outstanding overall performance. However, the existing fabrication techniques for C_f/UHTCMCs face significant engineering challenges, including high raw material costs and complex processing methods. Here we propose a cost-effective fabrication strategy. This approach ensures the oxidation and ablation resistance of the material by incorporating sufficient ZrB₂and SiC, followed by filling the remaining pores in the composite with in-situ derived pyrolytic carbon from furfuryl ketone resin, which significantly reduces fabrication costs and enables rapid densification. The C_f/ZrB₂-SiC-C composites produced by this strategy exhibit a flexural strength of 468 ± 18 MPa and a fracture toughness of 18.23 ± 1.14 MPa m^1/2. Furthermore, the composites remain non-ablative when exposed to temperatures of 2300 °C for extended periods, with a mass ablation rate of only 4.14 × 10⁻⁶ g/(mm²·s) after 400 s of testing. This strategy offers significant design versatility and can be applied to various ultra-high temperature ceramic systems, offering a novel and cost-effective approach to the development of thermal protection materials for hypersonic vehicles.