Matrix structure evolution and thermo-mechanical properties of carbon fiber-reinforced Al{sub 2}O{sub 3}-SiC-C castable composites

Highlights: • Carbon fibers are formed in Al{sub 2}O{sub 3}-SiC-C castable composites under the action of nano Ni. • Starting growth temperature is 900 °C and growth mechanism agrees with V–S model. • The high temperature strength of composites can be increased by above 40%. • The thermal shock resistance can be enhanced by above 20%. - Abstract: The spalling and corrosion during the thermal cycles are the main causes of the damages observed in Al{sub 2}O{sub 3}-SiC-C castable composites that are used in molten-iron system. Using the catalyst of nano Ni and ball pitch in the matrix, Al{sub 2}O{sub 3}-SiC-C castable composites were prepared with the anti-oxidant addition of silicon. The results indicate that the high temperature of the Al{sub 2}O{sub 3}-SiC-C castable composites can be increased by above 42%, and the thermal shock resistance can be enhanced by above 20% because the ball pitch is carbonized and releases C{sub x}H{sub y} vapor, which can be pyrolized to carbon atoms and subsequently deposited into carbon fibers under the catalyst action. The starting temperature of carbon fiber growth is approximately 900 °C, and their diameter and aspect ratio can increase with the rising temperature. The in-situ generation of carbon fibers in Al{sub 2}O{sub 3}-SiC-C castable composites can significantly improve the fibers’ thermo-mechanical properties.