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Ultra-high temperature ceramic matrix composite
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<h2 id="breakthroughs-in-research">Breakthroughs in research</h2> <p>The <a href="/facts/European_Commission/Cc5JgbEI">European Commission</a> funded a research project, C3HARME, under the NMP-19-2015 call of <a href="/facts/Framework_Programmes_for_Research_and_Technological_Development/Udy5lUQ7">Framework Programmes for Research and Technological Development</a> in 2016-2020 for the design, manufacturing and testing of a new class of ultra-refractory ceramic matrix composites reinforced with <a href="/facts/Silicon_carbide_fibers/CgN6hnuk">silicon carbide fibers</a> and <a href="/facts/Carbon_fibers/BTIgu1Jx">Carbon fibers</a> suitable for applications in severe aerospace environments.<a class="footnote-ref" id="fnref:39" href="#fn:39"><sup>39</sup></a> </p> <h2 id="challenges-in-manufacturing-and-machining">Challenges in manufacturing and machining</h2> <p>The manufacturing and machining of UHTCMCs present new challenges due to the unique properties of these advanced materials. Traditional manufacturing techniques such as casting and molding may not be suitable for UHTCMCs, requiring the development of specific methods like <a href="/facts/Chemical_vapor_infiltration/KSGAGQV4">chemical vapor infiltration (CVI)</a>,<a class="footnote-ref" id="fnref:40" href="#fn:40"><sup>40</sup></a> polymer infiltration and pyrolysis (PIP),<a class="footnote-ref" id="fnref:41" href="#fn:41"><sup>41</sup></a> reactive melt infiltration (RMI),<a class="footnote-ref" id="fnref:42" href="#fn:42"><sup>42</sup></a><a class="footnote-ref" id="fnref:43" href="#fn:43"><sup>43</sup></a> slurry impregnation and sintering (SIS)<a class="footnote-ref" id="fnref:44" href="#fn:44"><sup>44</sup></a> or by combining multiple processes in sequence.<a class="footnote-ref" id="fnref:45" href="#fn:45"><sup>45</sup></a> CVI involves the infiltration of a porous preform, typically made of fibers, with a gas-phase precursor that decomposes at high temperatures to form a ceramic matrix. The process begins by placing the fiber preform in a reaction chamber, where it is exposed to a gaseous precursor, such as silicon-containing compounds (e.g., <a href="/facts/Methane/kBHneYnh">CH4</a>, <a href="/facts/Silicon_tetrachloride/MXnhxpVK">SiCl4</a> or <a href="/facts/Silane/XNevDLgE">SiH4</a>) in the presence of heat. At elevated temperatures, the precursor gases react and deposit a solid ceramic material onto the fibers, forming a dense matrix. </p><p>The process also ensures and adequate bonding between the matrix and the reinforcing fibers, enhancing the mechanical properties and thermal stability of the composite. However, CVI is relatively slow due to the need for long infiltration times. The method is also sensitive to process conditions, requiring careful control of temperature, pressure, and precursor concentration to avoid defects like porosity or incomplete infiltration. </p><p>PIP involves multiple cycles polymer infiltration followed by pyrolysis, leading to high material performance but is time-consuming and costly due to the need for several infiltration and pyrolysis steps.<a class="footnote-ref" id="fnref:46" href="#fn:46"><sup>46</sup></a> RMI is faster, as molten metal or ceramic infiltrates the preform, forming a strong composite. However, it requires precise control of the high-temperature process and can be expensive depending on the materials used. SIS is the fastest process ensuring also the largest fraction of UHTC phases in the matrix, but it may face issues with uniformity, bonding between fibers and the matrix.<a class="footnote-ref" id="fnref:47" href="#fn:47"><sup>47</sup></a> Moreover, sintering occurs via hot pressing (HP) or spark plasma sintering (SPS)<a class="footnote-ref" id="fnref:48" href="#fn:48"><sup>48</sup></a> furnaces wich required mechanical prussere to produce a low porosity material,<a class="footnote-ref" id="fnref:49" href="#fn:49"><sup>49</sup></a> so the process allow to produce simple shape and scalability could be an issue.In addition, the consolidation of these materials is done combining a strong mechanical pressing during the sintering process at very high temperature. These furnaces allow simple shapes to be produced, and currently the largest furnaces to date on the market allow side plate sizes around half a meter. Scalability of the process is therefore limited by the ability of these special furnaces with mechanical pressing to exert and control high forces over large areas uniformly at very high temperature (usually graphite pistons and molds). </p><p>The choice of process depends on the desired material properties, cost constraints, and production scale. A comparison of mechanical properties and ablation resistance of similar UHTCMC materials obtained by different technologies is reported in ref <a class="footnote-ref" id="fnref:50" href="#fn:50"><sup>50</sup></a><a class="footnote-ref" id="fnref:51" href="#fn:51"><sup>51</sup></a> </p><p>Machining these materials is particularly challenging due to their high hardness and low fracture toughness (comparared to metals), which demand advanced tools and techniques to avoid cracking or delamination. Additionally, the anisotropic nature of fiber reinforced materials, arising from the directional arrangement of fibers, adds complexity to achieving precise shapes and finishes.<a class="footnote-ref" id="fnref:52" href="#fn:52"><sup>52</sup></a> Furthermore, maintaining the integrity of the fiber-matrix interface during processing is critical to preserving the material's mechanical properties. As a result, ongoing research is focused on optimizing manufacturing processes, improving tool materials, and developing novel machining strategies to meet the increasing demand for <a href="/facts/Ceramic_matrix_composite/zvty2Svr">CMCs</a> and UHTCMCs in industries such as aerospace, automotive, radioisotope formation<a class="footnote-ref" id="fnref:53" href="#fn:53"><sup>53</sup></a><a class="footnote-ref" id="fnref:54" href="#fn:54"><sup>54</sup></a> and rinnovable energies.<a class="footnote-ref" id="fnref:55" href="#fn:55"><sup>55</sup></a> Their compatibility with cells was studied for possible application in biomedical fields.<a class="footnote-ref" id="fnref:56" href="#fn:56"><sup>56</sup></a> </p> <h2 id="references">References</h2> <ol> <li id="fn:1"><p>Marumo, Tomoki; Koide, Noriatsu; Arai, Yutaro; Nishimura, Toshiyuki; Hasegawa, Makoto; Inoue, Ryo (October 2022). "Characterization of carbon fiber-reinforced ultra-high temperature ceramic matrix composites fabricated via Zr-Ti alloy melt infiltration". Journal of the European Ceramic Society. 42 (13): 5208–5219. doi:10.1016/j.jeurceramsoc.2022.06.040. S2CID 249838869. Retrieved 12 December 2023. <a href="https://www.sciencedirect.com/science/article/abs/pii/S0955221922004915" target="_blank">https://www.sciencedirect.com/science/article/abs/pii/S0955221922004915</a> <a href="#fnref:1" class="footnote-back-ref">↩</a></p></li> <li id="fn:2"><p>Mungiguerra, S.; Silvestroni, L.; Savino, R.; Zoli, L.; Esser, B.; Lagos, M.; Sciti, D. (2022-02-01). "Qualification and reusability of long and short fibre-reinforced ultra-refractory composites for aerospace thermal protection systems". Corrosion Science. 195: 109955. Bibcode:2022Corro.19509955M. doi:10.1016/j.corsci.2021.109955. ISSN 0010-938X. <a href="https://www.sciencedirect.com/science/article/abs/pii/S0010938X2100723X" target="_blank">https://www.sciencedirect.com/science/article/abs/pii/S0010938X2100723X</a> <a href="#fnref:2" class="footnote-back-ref">↩</a></p></li> <li id="fn:3"><p>Cheng, Tianbao; Zhang, Rubing; Pei, Yongmao; He, Rujie; Fang, Daining; Yang, Yazheng (12 June 2019). "Flexural properties of carbon-carbon composites at temperatures up to 2600 °C". Materials Research Express. 6 (8). Bibcode:2019MRE.....6h5629C. doi:10.1088/2053-1591/ab23c9. S2CID 181325974. Retrieved 12 December 2023. <a href="https://iopscience.iop.org/article/10.1088/2053-1591/ab23c9" target="_blank">https://iopscience.iop.org/article/10.1088/2053-1591/ab23c9</a> <a href="#fnref:3" class="footnote-back-ref">↩</a></p></li> <li id="fn:4"><p>Sciti, D.; Vinci, A.; Zoli, L.; Galizia, P.; Mor, M.; Fahrenholtz, W.; Mungiguerra, S.; Savino, R.; Caporale, A. M.; Airoldi, A. (2024-12-19). "Elevated temperature performance: Arc-Jet testing of carbon fiber reinforced ZrB₂ bars up to 2200 °C for strength retention assessment". Journal of Advanced Ceramics. doi:10.26599/JAC.2024.9221022. ISSN 2226-4108. <a href="https://www.sciopen.com/article/10.26599/JAC.2024.9221022" target="_blank">https://www.sciopen.com/article/10.26599/JAC.2024.9221022</a> <a href="#fnref:4" class="footnote-back-ref">↩</a></p></li> <li id="fn:5"><p>Galizia, Pietro; Vinci, Antonio; Zoli, Luca; Monteverde, Frederic; Binner, Jon; Venkatachalam, Vinothini; Lagos, Miguel.A.; Reimer, Thomas; Jain, Neraj; Sciti, Diletta (October 2021). "Retained strength of UHTCMCs after oxidation at 2278 K". Composites Part A: Applied Science and Manufacturing. 149: 106523. doi:10.1016/j.compositesa.2021.106523. ISSN 1359-835X. <a href="https://doi.org/10.1016/j.compositesa.2021.106523" target="_blank">https://doi.org/10.1016/j.compositesa.2021.106523</a> <a href="#fnref:5" class="footnote-back-ref">↩</a></p></li> <li id="fn:6"><p>Vinci, Antonio; Reimer, Thomas; Zoli, Luca; Sciti, Diletta (May 2021). "Influence of pressure on the oxidation resistance of carbon fiber reinforced ZrB2/SiC composites at 2000 and 2200 °C". Corrosion Science. 184: 109377. doi:10.1016/j.corsci.2021.109377. ISSN 0010-938X. <a href="https://doi.org/10.1016/j.corsci.2021.109377" target="_blank">https://doi.org/10.1016/j.corsci.2021.109377</a> <a href="#fnref:6" class="footnote-back-ref">↩</a></p></li> <li id="fn:7"><p>Vinci, Antonio; Zoli, Luca; Galizia, Pietro; Sciti, Diletta (December 2020). "Influence of Y2O3 addition on the mechanical and oxidation behaviour of carbon fibre reinforced ZrB2/SiC composites". Journal of the European Ceramic Society. 40 (15): 5067–5075. doi:10.1016/j.jeurceramsoc.2020.06.043. ISSN 0955-2219. <a href="https://doi.org/10.1016/j.jeurceramsoc.2020.06.043" target="_blank">https://doi.org/10.1016/j.jeurceramsoc.2020.06.043</a> <a href="#fnref:7" class="footnote-back-ref">↩</a></p></li> <li id="fn:8"><p>Servadei, Francesca; Zoli, Luca; Vinci, Antonio; Galizia, Pietro; Sciti, Diletta (2021-08-15). "Significant improvement of the self-protection capability of ultra-high temperature ceramic matrix composites". Corrosion Science. 189: 109575. Bibcode:2021Corro.18909575S. doi:10.1016/j.corsci.2021.109575. ISSN 0010-938X. <a href="https://www.sciencedirect.com/science/article/abs/pii/S0010938X21003413" target="_blank">https://www.sciencedirect.com/science/article/abs/pii/S0010938X21003413</a> <a href="#fnref:8" class="footnote-back-ref">↩</a></p></li> <li id="fn:9"><p>Mor, Matteo; Vinci, Antonio; Failla, Simone; Galizia, Pietro; Zoli, Luca; Sciti, Diletta (2023-01-05). "A novel approach for manufacturing of layered, ultra-refractory composites using pliable, short fibre-reinforced ceramic sheets". Journal of Advanced Ceramics. 12 (1): 155–168. doi:10.26599/JAC.2023.9220674. ISSN 2226-4108. <a href="https://www.sciopen.com/article/10.26599/JAC.2023.9220674" target="_blank">https://www.sciopen.com/article/10.26599/JAC.2023.9220674</a> <a href="#fnref:9" class="footnote-back-ref">↩</a></p></li> <li id="fn:10"><p>Sciti, D.; Zoli, L.; Vinci, A.; Silvestroni, L.; Mungiguerra, S.; Galizia, P. (May 2021). "Effect of PAN-based and pitch-based carbon fibres on microstructure and properties of continuous Cf/ZrB2-SiC UHTCMCs". Journal of the European Ceramic Society. 41 (5): 3045–3050. doi:10.1016/j.jeurceramsoc.2020.05.032. ISSN 0955-2219. <a href="https://doi.org/10.1016/j.jeurceramsoc.2020.05.032" target="_blank">https://doi.org/10.1016/j.jeurceramsoc.2020.05.032</a> <a href="#fnref:10" class="footnote-back-ref">↩</a></p></li> <li id="fn:11"><p>Zoli, L.; Medri, V.; Melandri, C.; Sciti, D. (2015-12-01). "Continuous SiC fibers-ZrB2 composites". Journal of the European Ceramic Society. 35 (16): 4371–4376. doi:10.1016/j.jeurceramsoc.2015.08.008. ISSN 0955-2219. <a href="https://www.sciencedirect.com/science/article/abs/pii/S0955221915300911" target="_blank">https://www.sciencedirect.com/science/article/abs/pii/S0955221915300911</a> <a href="#fnref:11" class="footnote-back-ref">↩</a></p></li> <li id="fn:12"><p>Zoli, Luca; Servadei, Francesca; Failla, Simone; Mor, Matteo; Vinci, Antonio; Galizia, Pietro; Sciti, Diletta (2024-02-01). "ZrB2–SiC ceramics toughened with oriented paper-derived graphite for a sustainable approach". Journal of Advanced Ceramics. 13 (2): 207–219. doi:10.26599/JAC.2024.9220842. ISSN 2226-4108. <a href="https://www.sciopen.com/article/10.26599/JAC.2024.9220842" target="_blank">https://www.sciopen.com/article/10.26599/JAC.2024.9220842</a> <a href="#fnref:12" class="footnote-back-ref">↩</a></p></li> <li id="fn:13"><p>"c³harme". www.c3harme.eu. <a href="http://www.c3harme.eu" target="_blank">http://www.c3harme.eu</a> <a href="#fnref:13" class="footnote-back-ref">↩</a></p></li> <li id="fn:14"><p>Sciti, Diletta; Silvestroni, Laura; Monteverde, Frédéric; Vinci, Antonio; Zoli, Luca (2018-10-17). "Introduction to H2020 project C3HARME – next generation ceramic composites for combustion harsh environment and space". Advances in Applied Ceramics. 117 (sup1): s70 – s75. Bibcode:2018AdApC.117S..70S. doi:10.1080/17436753.2018.1509822. ISSN 1743-6753. <a href="https://doi.org/10.1080%2F17436753.2018.1509822" target="_blank">https://doi.org/10.1080%2F17436753.2018.1509822</a> <a href="#fnref:14" class="footnote-back-ref">↩</a></p></li> <li id="fn:15"><p>Mungiguerra, Stefano; Di Martino, Giuseppe D.; Cecere, Anselmo; Savino, Raffaele; Zoli, Luca; Silvestroni, Laura; Sciti, Diletta (August 2020). "Ultra-high-temperature testing of sintered ZrB2-based ceramic composites in atmospheric re-entry environment". International Journal of Heat and Mass Transfer. 156: 119910. Bibcode:2020IJHMT.15619910M. doi:10.1016/j.ijheatmasstransfer.2020.119910. ISSN 0017-9310. <a href="https://doi.org/10.1016/j.ijheatmasstransfer.2020.119910" target="_blank">https://doi.org/10.1016/j.ijheatmasstransfer.2020.119910</a> <a href="#fnref:15" class="footnote-back-ref">↩</a></p></li> <li id="fn:16"><p>Baker, B.; Venkatachalam, V.; Zoli, L.; Vinci, A.; Failla, S.; Sciti, D.; Binner, J. (December 2021). "Ablation behaviour of carbon fibre ultra-high temperature composites at oblique angles of attack". Materials & Design. 212: 110199. doi:10.1016/j.matdes.2021.110199. ISSN 0264-1275. <a href="https://doi.org/10.1016/j.matdes.2021.110199" target="_blank">https://doi.org/10.1016/j.matdes.2021.110199</a> <a href="#fnref:16" class="footnote-back-ref">↩</a></p></li> <li id="fn:17"><p>Sciti, D.; Zoli, L.; Silvestroni, L.; Cecere, A.; Martino, G.D. Di; Savino, R. (2016). "Design, fabrication and high velocity oxy-fuel torch tests of a C f -ZrB 2 - fiber nozzle to evaluate its potential in rocket motors". Materials & Design. 109: 709–717. doi:10.1016/j.matdes.2016.07.090. <a href="/wiki/Doi_(identifier)" target="_blank">/wiki/Doi_(identifier)</a> <a href="#fnref:17" class="footnote-back-ref">↩</a></p></li> <li id="fn:18"><p>Mungiguerra, Stefano; Di Martino, Giuseppe D.; Savino, Raffaele; Zoli, Luca; Silvestroni, Laura; Sciti, Diletta (December 2020). "Characterization of novel ceramic composites for rocket nozzles in high-temperature harsh environments". International Journal of Heat and Mass Transfer. 163: 120492. Bibcode:2020IJHMT.16320492M. doi:10.1016/j.ijheatmasstransfer.2020.120492. ISSN 0017-9310. <a href="https://doi.org/10.1016/j.ijheatmasstransfer.2020.120492" target="_blank">https://doi.org/10.1016/j.ijheatmasstransfer.2020.120492</a> <a href="#fnref:18" class="footnote-back-ref">↩</a></p></li> <li id="fn:19"><p>Sciti, Diletta; Vinci, Antonio; Zoli, Luca; Galizia, Pietro; Failla, Simone; Mungiguerra, Stefano; Martino, Giuseppe D. Di; Cecere, Anselmo; Savino, Raffaele (2023-07-05). "Propulsion tests on ultra-high-temperature ceramic matrix composites for reusable rocket nozzles". Journal of Advanced Ceramics. 12 (7): 1345–1360. doi:10.26599/JAC.2023.9220759. 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Bibcode:2016PrAeS..84....1S. doi:10.1016/j.paerosci.2016.04.001. hdl:1826/10119. <a href="/wiki/Bibcode_(identifier)" target="_blank">/wiki/Bibcode_(identifier)</a> <a href="#fnref:21" class="footnote-back-ref">↩</a></p></li> <li id="fn:22"><p>Vinci, Antonio; Zoli, Luca; Sciti, Diletta; Watts, Jeremy; Hilmas, Greg E.; Fahrenholtz, William G. (April 2019). "Mechanical behaviour of carbon fibre reinforced TaC/SiC and ZrC/SiC composites up to 2100°C". Journal of the European Ceramic Society. 39 (4): 780–787. doi:10.1016/j.jeurceramsoc.2018.11.017. ISSN 0955-2219. S2CID 139993345. <a href="/wiki/Doi_(identifier)" target="_blank">/wiki/Doi_(identifier)</a> <a href="#fnref:22" class="footnote-back-ref">↩</a></p></li> <li id="fn:23"><p>Mungiguerra, S.; Di Martino, G.D.; Cecere, A.; Savino, R.; Silvestroni, L.; Vinci, A.; Zoli, L.; Sciti, D. (April 2019). "Arc-jet wind tunnel characterization of ultra-high-temperature ceramic matrix composites". Corrosion Science. 149: 18–28. 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