<p>Arbon/carbon (C/C) composites have emerged as ideal candidates for thermal protection systems in aerospace vehicles due to their exceptional high-temperature mechanical properties. However, their rapid ablation in high-temperature oxidative environments severely limits engineering applications. To address this bottleneck, this study proposes a ZrC-30vol.%SiC (ZS3) ultra-high temperature ceramic coating system with an SiC transition layer. The composite coating was fabricated on C/C substrates via vacuum plasma spraying technology, and its anti-ablation mechanisms were systematically investigated through multi-scale analytical approaches. A three-dimensional transient thermo-structural coupling model was established using the ANSYS software, incorporating the " birth and death element " technique to simulate dynamic evolution of coating ablation morphology. This enabled quantitative characterization of spatiotemporal temperature distribution and Gaussian-type temperature gradient characteristics under laser irradiation. Transient thermo-structural coupling analysis elucidated the thermal stress evolution mechanisms in the coating-transition layer-substrate system during ablation. Combined CO<sub>2</sub> laser ablation experiments and microstructural characterization revealed that the ZS3 composite coating exhibits significantly superior ablation resistance compared to pure ZrC coatings, attributed to the formation of a dense ZrO<sub>2</sub>-SiO<sub>2</sub> oxide layer. The synergistic failure mechanism involving oxidative phase transformation and thermal stress was comprehensively revealed. This research provides theoretical foundations for damage assessment and optimized design of ultra-high temperature ceramic coatings under high-energy laser irradiation.</p>

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Ablative Properties of ZrC-Based Ultra-High Temperature Ceramic Coatings under Intense Laser Irradiation: Finite Element Simulation and Experiment

  • Lingling Xie,
  • Guangxin Luo,
  • Tianyu Fang,
  • Yaran Niu,
  • Ziyu Wang,
  • Shichao Zhu,
  • Xuebin Zheng

摘要

Arbon/carbon (C/C) composites have emerged as ideal candidates for thermal protection systems in aerospace vehicles due to their exceptional high-temperature mechanical properties. However, their rapid ablation in high-temperature oxidative environments severely limits engineering applications. To address this bottleneck, this study proposes a ZrC-30vol.%SiC (ZS3) ultra-high temperature ceramic coating system with an SiC transition layer. The composite coating was fabricated on C/C substrates via vacuum plasma spraying technology, and its anti-ablation mechanisms were systematically investigated through multi-scale analytical approaches. A three-dimensional transient thermo-structural coupling model was established using the ANSYS software, incorporating the " birth and death element " technique to simulate dynamic evolution of coating ablation morphology. This enabled quantitative characterization of spatiotemporal temperature distribution and Gaussian-type temperature gradient characteristics under laser irradiation. Transient thermo-structural coupling analysis elucidated the thermal stress evolution mechanisms in the coating-transition layer-substrate system during ablation. Combined CO2 laser ablation experiments and microstructural characterization revealed that the ZS3 composite coating exhibits significantly superior ablation resistance compared to pure ZrC coatings, attributed to the formation of a dense ZrO2-SiO2 oxide layer. The synergistic failure mechanism involving oxidative phase transformation and thermal stress was comprehensively revealed. This research provides theoretical foundations for damage assessment and optimized design of ultra-high temperature ceramic coatings under high-energy laser irradiation.