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Aeropro

Synthesis of ZrB2–SiC–ZrC nanostructured powders for ultra-high temperature resistance by sol-gel method

Ultra-high temperature ceramics (UHTCs) are an ad hoc type of ceramics with robust resistance against extremely high temperature, being thought of as a potential candidate as thermal protected materials. Owing to their outstanding performance under extreme conditions, these kinds of materials are particularly suitable for high-temperature applications, such as rocket propulsion systems, hypersonic and re-entry vehicles, aerospace, and other high-tech fields as well.

 Zirconium Diboride (ZrB2) is a widely researched UHTCs renowned for its exceptional physical and chemical properties, such as high melting point (3250 °C) and hardness (22 GPa), good thermal shock resistance and moderate chemical stability despite the fact that it was infamous for poor oxidation resistance under elevated temperature. To cope with this thorny conundrum, silicon carbide (SiC) and zirconium carbide (ZrC) are often introduced to ZrB2 matrix in order to optimize its high-temperature oxidation resistance, suppress the growth of silicon carbide depletion layers, and prevent abnormal grain growth at elevated temperatures. As a consequence, the material's physical and mechanical properties will be improved.

This study conducted the sol-gel method combined with high-temperature sintering to synthesize a ternary ceramic material with ZrB2-SiC-ZrC nano scale structures. The influence of composition ratios, sintering temperature, and other process parameters on the morphology and crystalline phases were discussed.

Metal Oxide Ceramics

Ceramic aerogels, composed of porous solid gels with air as the dispersed phase, exhibit extremely high porosity and an ultra-low thermal conductivity (0.013 W/m·K).  They have garnered significant attention in the field of thermal insulation recently. Moreover, utilizing flexible ceramic nanofibers to construct aerogels results in significant macroscopic elastic deformation, which improves the inherent brittleness of ceramic materials.

Our Present Work

In our present work, we use the technology called electrospinning to synthesize the ceramic nanofibers. As for the aerogels we use freeze-casting to construct the three-dimensional ceramics nanofiber aerogels(CNFAs)

Schematic illustration of CNFAs process flow.

Besides, by doping multiple elements, we synthesize high-entropy materials. A promising thermal barrier coating (TBC) material, lanthanum zirconate, was chosen. Through the electrospinning process, ceramic nanofibers were prepared and doped with lanthanum, rubidium, samarium, gadolinium, and yttrium to form a single phase, polycrystalline high-entropy ceramic nanofibers, (La0.2Nd0.2Sm0.2Gd0.2Y0.2)2Zr2O7. Compared to lanthanum zirconate, it exhibited better high-temperature stability and effectively reduced the thermal conductivity by 68%.

XRD pattens and their local enlargement of La2Zr2O7 and (5RE)2Zr2O7

SEM images of (a)-(d) La2Zr2O7 and (e)-(h) (5RE)2Zr2O7 calcinated at different temperatures

Future Work

Besides trying to complete the process optimization on electrospinning and the freeze-casting method we would also try to explore other unique materials or the different construction for the ceramic nanofibers or aerogels to have better performance on thermal insulation. Otherwise, we were going to use the ceramic nanofibers or aerogels on other applications, for example, electrochemical catalyst or passive radiative cooling, and so on.

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