Phenol-formaldehyde coating to improve the debris formation resistance of carbon foam

Dip coating of carbon foam with phenol-formaldehyde (PF) resin solutions has been studied to improve its debris formation resistance. The PF coating increased the specific strength and impact resistance of the carbon foam without affecting its interconnected cellular structure, thermal conductivity and fire resistance. A friability test showed a decrease in the debris formation from 48 to 2.7wt% when the PF loading increased from 0 to 76wt%. The increase in the impact and debris formation resistance with PF coating is due to the absorption of impact energy for debonding at the carbon–PF coating interface. •Debris formation in carbon foams is a matter of concern.•Simple PF resin coating on carbon foam is done to reduce friability.•The debris formation decreased from 48 to 2.8wt% after PF coating.•The mechanism of debris formation resistance was established.•Coating does not affect cellular structure and thermal conductivity of carbon foam.