Improved Ablation Resistance of Carbon∓Phenolic Composites by Introducing Zirconium Diboride Particles

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Improved Ablation Resistance of Carbon∓Phenolic Composites by Introducing Zirconium Diboride Particles Composites: Part B 47 (2013) 320–325 Contents lists available at SciVerse ScienceDirect Composites: Part B journal homepage: www.elsevier.com/locate/compositesb Improved ablation resistance of carbon–phenolic composites by introducing zirconium diboride particles ⇑ Yaxi Chen a, , Ping Chen a, Changqing Hong b, Baoxi Zhang b, David Hui c a School of Chemical Engineering, Dalian University of Technology, Dalian, Liaoning 116024, PR China b Key Laboratory of Science and Technology for Advanced Composites in Special Environments, Harbin Institute of Technology, Harbin, Heilongjiang 150001, PR China c Dept. of Mechanical Engineering, University of New Orleans, New Orleans, LA 70124, United States article info abstract Article history: Carbon–phenolic (C–Ph) composites are well fabricated to meet the requirements of thermal protection Received 13 September 2012 system by introducing ZrB2 particles. TG analysis demonstrates that the existence of ZrB2 particles could Received in revised form 19 October 2012 obviously aggrandize the char yield of phenolic, although it does not enhance the thermal stability of Accepted 1 November 2012 phenolic. What is more, the employed method of introducing ZrB could notably improve ablation resis- Available online 29 November 2012 2 tance and insulation performance of C–Ph composites, which is mainly owing to the formation of ZrO2 and B2O3. As depicted in the microstructure, the ablation rate of matrix is evidently higher than carbon Keywords: fibers in the C–Ph composites. However, the ablation rate of carbon fibers is identical to matrix in Z C–Ph A. Polymer–matrix composites (PMCs) composites. B. Thermal properties D. Thermal analysis Ó 2012 Elsevier Ltd. All rights reserved. E. Thermosetting resin Ablation resistance 1. Introduction vapor grown carbon fibers, exhibit extremely good erosion resis- tance and display less weight loss compared with the composites A spacecraft, entering or traveling through an atmosphere at (composed of woven ex-rayon carbon fibers, carbon black fillers very high speed when typically subjected to a high heat flux, re- and phenolic) [8]. Furthermore, it appears to be a far better insula- quires a thermal protection system (TPS) to maintain a relatively tor. The C–Ph composites, treated with polyhedral oligomeric ‘‘cold’’ temperature, so lots of thermal protection materials have silsequioxanes, emerge a better ablative performance [9].H3PO4À been extensively investigated to protect space vehicle against the coated carbon fiber–phenolic composites can undergo stronger aerodynamic heating encountered in hypersonic flight [1]. The thermomechanical influence during ablation, and give a lower ero- ablation materials represent one of the traditional approaches to sion rate to retard the ablation process [10]. The composites, mak- thermal protection systems which have been vastly explored and ing of three-dimension reticulated SiC ceramic, carbon fibers and investigated [2,3]. The mechanism of ablation materials is that a boron-modified phenolic, have less linear ablation rate compared quantity of energy is excellently absorbed by removed material. with pure boron modified phenolic or carbon fiber/boron-modified The carbon–phenolic composites (C–Ph) are considered exten- phenolic composites [11]. Nanosilica powder modified sively to be efficient ablative thermal protection materials [4,5], rayon-based carbon–fabric/phenolic composites reveal improved owing to their excellent ablative resistant properties. Ablative ablation resistance, reduced thermal conductivity and higher in- resistance of C–Ph composites plays a very important role in aero- ter-laminar shear strength at a controlled quantity [12]. In general, space application when subject to high temperatures. Many efforts these methods are frequently utilized to improve the ablative have been made to evidently improve this performance of C–Ph performance of C–Ph composites by modification carbon fibers or composites in recent years. Boron modified phenolic is synthesized phenolic, interface treatment and addition of other compounds. from boric acid, phenol, and formaldehyde, and it is widely used as Zirconium diboride (ZrB2) has high melting point (P3000 °C), matrix of C–Ph ablation composites, because of its good heat resis- which oxidizes to ZrO2 and B2O3 [13]. Some previous works have tance, mechanical properties, electric properties and absorbance of been well reported that the formation of protective ZrO2 coating neutron radiation [6,7]. C–Ph composites, containing 30–45 wt% could markedly improve ablation resistance of carbon composites [14]. In addition, ZrB2 and B4C particles are applied as oxidation inhibitors to improve significantly ablation performance of bulk ⇑ Corresponding author. Tel./fax: +86 451 86403016. C–C composites [15]. However, the effects of ZrB2 on the ablation E-mail address: [email protected] (Y. Chen). performance of C–Ph composites are still unclear. 1359-8368/$ - see front matter Ó 2012 Elsevier Ltd. All rights reserved. http://dx.doi.org/10.1016/j.compositesb.2012.11.007 Y. Chen et al. / Composites: Part B 47 (2013) 320–325 321 In this article, we extensive review the current state of this 3. Results and discussion exciting field, and emphasize that the effects of introducing ZrB2 particles on the ablation and insulation performance of C–Ph com- 3.1. Thermogravimetry (TG) and X-ray diffraction analysis posites. It is well fabricated by impregnating method that phenolic resin and ZrB2 particles fill the pores of the carbon fiber fabric. The The thermal stabilities of cured phenolic and the cured mixture, ablation performance of introducing ZrB2 particles modified car- containing phenolic and ZrB2 (mass ration 1:0.2), are explored by bon–phenolic (Z C–Ph) composites is reasonable tested by oxy- thermal gravimetric analysis. Thermal gravimetric curves are pre- gen–acetylene, and the temperatures of the ablated surface and sented in Fig. 2. the back surface are real-time monitored. The influence of ZrB2 As well known, the phenolic has pyrolysis phenomenon when on thermal stability of phenolic is investigated extensively. In addi- the temperature exceeds 300 °C, and the weight loss below tion, the mechanisms of improving ablation resistance are deeply 300 °C is not mainly owing to the pyrolysis of phenolic but the discussed. post-cured process [16].InFig. 2, we could find that the mixture and phenolic all have the thermal degradation phenomenon when 2. Experimental the temperature goes up to 300 °C. More and more thermal degra- dation byproducts are found when the temperature continues to For the purpose of proper demonstration, the proposed three- creep from 480 °C to 650 °C. It is clear that ZrB2 particle does not dimensional carbon fibers fabric was impregnated in mixture. change the temperature distribution of phenolic pyrolysis, and The three-dimensional carbon fibers matrix was defined as the thermal stability of phenolic does not increase significantly. 40  40  40 mm (with the density q = 0.185 g/cm3). The mixture The char yield of phenolic and phenolic containing ZrB2 at 1000 °C are 67.3% and 73.4%, respectively. If calculated weight loss contained ethanol, phenolic and ZrB2 powders at the mass ration of 1:1:0.2. It was the optimum to manufacture Z C–Ph composites was owing to the pyrolysis of phenolic, and ZrB2 weight was con- which has implied in our previous work. The three-dimensional sidered to be constant, the char yield of the mixture at 1000 °C carbon fibers fabric was put into the mixture for 20 min. Then should be 72.7%. This value is lower than the measured value of we left the fabric over 24 h to evaporate the solvent. The heating phenolic contains ZrB2. Therefore, the weight gain reactions should cure was done in 30 min, 90 min and 180 min in an oven at be occurred in this condition. 80 °C, 110 °C and 150 °C, respectively. In addition, the heating rate Fig. 3 reveals that the XRD patterns of the products after TG was approximately 1 °C/min, and sample cooling was completed at analysis. The XRD spectrum for the mixture demonstrates the for- the room temperature. The cured fabric (0.515 g/cm3) was divided mation of ZrO2, which results from the reactions between ZrB2 and into smaller sample with the size of £25  20 mm for oxygen– the pyrolysis products of phenolic in N2 atmosphere. It is well acetylene testing, and the C–Ph composites (0.491 g/cm3) was also known that the main pyrolysis products of phenolic include hydro- decollate to sub-sample of £25  20 mm. This mixture contains gen, methane, slight amount of ethane, water, small amount of car- ethanol and phenolic at the mass ration of 1:1. bon dioxide, carbon monoxide and porous amorphous carbon (the Thermogravimetry (TG) analysis was carried out by TGA/ char from phenolic) [16]. Two reactions of forming ZrO2 are given SDTA851e (Switzerland). The samples were placed in alumina cru- by: cibles, and heated from normal temperature (21 °C) to 1000 °C ZrB2ðsÞþ5COðgÞ¼ZrO2ðsÞþB2O3ðgÞþ5CðsÞð1Þ with increased heating rate of 5 °C/min in N2 atmosphere. The phase composition was analyzed by an X-ray diffraction device 2ZrB2ðsÞþ5CO2ðgÞ¼2ZrO2ðsÞþ2B2O3ðgÞþ5CðsÞð2Þ (Cu Ka radiation, D/max-RB, Japan). Ablation performance was The byproduct of B2O3 is not detected by XRD due to its evapo- tested by oxygen–acetylene. Scheme of the ablation experiments ration under N2 atmosphere [17–19]. Therefore, the increased char medium is shown in Fig. 1. The flow rates of oxygen and acetylene yield of the mixture contributes to the formation of ZrO2(s) and were 500 l/h and 400 l/h, respectively. The oxygen–acetylene gun C(s). As shown in Fig. 3, broad peaks (a and b) are observed at 2h with 2 mm dimension was perpendicular to the surface of the angles of about 24°and 44°, respectively. They are characteristics specimen, and the distance from gun to the surface of the specimen of amorphous carbon from phenolic [20]. However, these broad was 50 mm.
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