Ultra-High-Temperature Ceramic Coatings for Oxidation Protection of Carbon-Carbon Composites

Carbon–carbon (C–C) composites are attractive materials for hypersonic flight vehicles but they oxidize in air at temperatures >500°C and need thermal protection systems to survive aerothermal heating. We investigated using multilayers of high‐temperature ceramics such as ZrB2 and SiC to protect C–C against oxidation. Our approach combines pretreatment and processing steps to create continuous and adherent high‐temperature ceramic coatings from infiltrated preceramic polymers. We tested our protective coatings at temperatures above 2600°C at the National Solar Thermal Testing Facility using controlled cold‐wall heat flux profiles reaching a maximum of 680 W/cm2.