Advanced nano-composite coatings of ZrB₂/ZrC/SiC on carbon fibers via eco-friendly precursor synthesis

This study presents a comprehensive investigation into the synthesis and characterization of ZrB2/ZrC/SiC composite coatings on carbon fiber substrates via a solution-based process followed by high-temperature pyrolysis. The precursor solution was prepared using Gum Ghatti (GG), zirconyl chloride, tetraethyl orthosilicate, and boric acid. Optimization of precursor concentration and molar ratios was performed to achieve suitable viscosity and composition. The pyrolysis process was conducted in an argon atmosphere, resulting in the formation of well-defined ZrB2, ZrC, and SiC phases. XRD analysis confirmed the phase composition, while SEM imaging revealed spheroidal particle aggregates with a uniform distribution of composite phases. TG-DTA analysis reveals the thermal decomposition behavior, highlighting distinct stages of mass loss and phase transformations. Coated carbon fibers exhibited enhanced oxidation resistance, as evidenced by TGA analysis. SEM analysis confirmed the uniform distribution and adhesion of the composite matrix on the carbon fiber substrate. This study demonstrates the successful synthesis of ZrB2/ZrC/SiC composite coatings with promising thermal properties for advanced applications. [Display omitted] •Eco-friendly ZrB₂/ZrC/SiC composite coatings developed for carbon fiber using a novel Gum Ghatti-based precursor.•High-temperature pyrolysis at 1400°C resulted in well-defined ZrB₂, ZrC, and SiC phases with enhanced oxidation resistance.•SEM and EDX analyses confirm uniform coating, strong adhesion on the carbon fiber substrates, and no oxide impurities detected.•Composite coatings showed excellent oxidation resistance, enhancing the high-temperature performance of carbon fiber.