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<p>Phenolic Impregnated Carbon Ablator (PICA) remains a cornerstone of carbon-based Thermal Protection Systems (TPS), yet its performance in extreme hypersonic environments is often limited by oxidation and mechanical erosion. This study develops three novel variants of compression-molded conformal PICA, reinforced with Ultrahigh Temperature Ceramics (UHTCs) ZrB<sub>2</sub> and SiC and subsequently surface-modified with Polycarbosilane (PCS) and Organopolysilazane (OPSZ). Mechanical testing and morphological analysis via SEM were conducted to evaluate the synergistic effects of these modifications on structural integrity and ablation resistance at heat fluxes of 2 and 4 MW/m<sup>2</sup>. Results reveal a significant reduction in linear ablation rates, with PCS and OPSZ variants achieving 0.060&#xa0;mm/sec and 0.068&#xa0;mm/sec, respectively, representing a 23 ~ 28% improvement over bare PICA at 4 MW/m<sup>2</sup>. Crucially, microstructural analysis reveals that the surface modification promotes a transition from erosion-dominated recession to a diffusion-limited oxidation regime. This is attributed to the synergistic formation of a coherent, silicon-rich ceramic protective layer (SiO<sub>X</sub>, SiO<sub>2</sub>) that densifies the surface and anchors the UHTC particles, effectively shielding the underlying carbonaceous fibrous network from severe ablation plumes. These findings provide a scalable methodology for tailoring lightweight, high-performance ablators for next-generation aerospace missions.</p>

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Modification of mechanical and ablation resistance of novel compression molded conformal phenolic impregnated carbon ablator (PICA) through surface modification of polycarbosilane, PCS, and organopolysilazane, OPSZ

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Masood Karim,
  • Salman Ahmad,
  • Ali Javed,
  • Waleed Aslam,
  • Kashif Mehmood

摘要

Phenolic Impregnated Carbon Ablator (PICA) remains a cornerstone of carbon-based Thermal Protection Systems (TPS), yet its performance in extreme hypersonic environments is often limited by oxidation and mechanical erosion. This study develops three novel variants of compression-molded conformal PICA, reinforced with Ultrahigh Temperature Ceramics (UHTCs) ZrB2 and SiC and subsequently surface-modified with Polycarbosilane (PCS) and Organopolysilazane (OPSZ). Mechanical testing and morphological analysis via SEM were conducted to evaluate the synergistic effects of these modifications on structural integrity and ablation resistance at heat fluxes of 2 and 4 MW/m2. Results reveal a significant reduction in linear ablation rates, with PCS and OPSZ variants achieving 0.060 mm/sec and 0.068 mm/sec, respectively, representing a 23 ~ 28% improvement over bare PICA at 4 MW/m2. Crucially, microstructural analysis reveals that the surface modification promotes a transition from erosion-dominated recession to a diffusion-limited oxidation regime. This is attributed to the synergistic formation of a coherent, silicon-rich ceramic protective layer (SiOX, SiO2) that densifies the surface and anchors the UHTC particles, effectively shielding the underlying carbonaceous fibrous network from severe ablation plumes. These findings provide a scalable methodology for tailoring lightweight, high-performance ablators for next-generation aerospace missions.