CNT增韧ZrO2/BN陶瓷涂层改性纳米孔酚醛树脂基复合材料的制备及耐烧蚀性能

Preparation and ablation resistance of CNT-toughened ZrO2/BN ceramic coating modified nanoporous phenolic resin matrix composites

  • 摘要: 纳米孔酚醛树脂基复合材料(NPCs)因其具有轻质高强、耐高温烧蚀、高效隔热、易大尺寸成型等优点,在新一代热防护系统中具有广阔的应用前景。但在高热流环境中,材料热解碳层易氧化破坏,进而引发烧蚀后退与机械剥蚀。本文采用刷涂工艺在针刺石英纤维预制体表面构筑ZrO2/BN陶瓷涂层,并引入碳纳米管(CNT)调控涂层-基体界面,通过树脂浸渍-溶胶-凝胶-常压干燥过程制备了CNT增韧ZrO2/BN陶瓷涂层改性NPCs。系统分析了涂层刷涂量和碳纳米管含量对复合材料耐烧蚀性能的影响。结果表明,随ZrO2/BN涂层刷涂量增加,径向/轴向热导率比值从0.81增大到1.76,强化了面内热扩散能力;在2000℃、30 s氧乙炔烧蚀条件下,ZB/NPC-0.4的质量烧蚀速率和线烧蚀速率分别由未刷涂涂层的NPC-0.27的20.18 mg/s和25.3 μm/s降至14.28 mg/s和14.07 μm/s,分别降低了29.2%和44.4%,表明陶瓷涂层抑制了基体热解产物快速逸出和表面固相损失,并在厚度方向形成了有效屏障,从而能够延缓火焰向内部纤维/树脂骨架穿透。引入1% CNT后,ZBC/NPC-0.4-1样品的线烧蚀速率进一步降至12.32 μm/s,较ZB/NPC-0.4降低了12.4%。烧蚀表面粗糙度在1600℃、1800℃和2000℃下分别降低了63.1%、58.1%和66.8%,有效抑制了涂层翘曲与机械剥蚀。微观结构分析表明,ZrO2/BN在高温下形成致密多晶陶瓷层,碳纳米管促进残碳网络稳定并缓释热应力,两者协同提高了轻质纳米孔酚醛复合材料的表面完整性和耐烧蚀能力。

     

    Abstract: Nanoporous phenolic resin matrix composites (NPCs) have broad application prospects in new-generation thermal protection systems owing to their advantages of low density, high strength, excellent high-temperature ablation resistance, efficient thermal insulation, and ease of large-scale fabrication. However, under high heat flux environments, the pyrolytic carbon layer of these materials is prone to oxidative damage, which further induces ablation recession and mechanical erosion. In this work, ZrO2/BN ceramic coatings were constructed on the surface of needled quartz fiber preforms via a brushing process, and carbon nanotubes (CNTs) were introduced to regulate the coating-matrix interface. CNT-toughened ZrO2/BN ceramic coating-modified NPCs were prepared through a resin impregnation-sol-gel-ambient pressure drying process. The effects of coating loading and CNT content on the ablation resistance of the composites were systematically investigated. The results show that with the increase of ZrO2/BN coating loading, the ratio of radial to axial thermal conductivity rises from 0.81 to 1.76, significantly enhancing the in-plane heat diffusion capability. Under the oxy-acetylene ablation condition of 2000℃ for 30 s, the mass ablation rate and linear ablation rate of ZB/NPC-0.4 decrease from 20.18 mg/s and 25.3 μm/s (for the uncoated NPC-0.27) to 14.28 mg/s and 14.07 μm/s, corresponding to reductions of 29.2% and 44.4%, respectively. This indicates that the ceramic coatings inhibit the rapid escape of matrix pyrolysis products and surface solid phase loss, and form an effective barrier in the thickness direction, thereby delaying the penetration of flame into the internal fiber/resin skeleton. With the addition of 1 wt.% CNTs, the linear ablation rate of ZBC/NPC-0.4-1 further decreases to 12.32 μm/s, a reduction of 12.4% compared with ZB/NPC-0.4. The ablation surface roughness is reduced by 63.1%, 58.1%, and 66.8% at 1600℃, 1800℃, and 2000℃, respectively, effectively suppressing coating warpage and mechanical erosion. Microstructural analysis reveals that ZrO2/BN forms a dense polycrystalline ceramic layer at high temperatures, while CNTs promote the stability of the residual carbon network and relieve thermal stress. The synergistic effect of the two significantly improves the surface integrity and ablation resistance of lightweight nanoporous phenolic composites.

     

/

返回文章
返回