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SiBCN–ZrO2 aerogel-modified carbon-bonded carbon fiber composite with enhancement of in-plane thermal conductivity for thermal protection applications

Xinqiao Wang,Yongqiang Tao,Ning Zhou,Xiaoguang Luo,Bin Ma,Baosheng Xu

Hypersonic vehicles operate under conditions of extreme aerodynamic heating, which presents significant challenges for the design of thermal protection system (TPS). Carbon-bonded carbon fiber (CBCF) composites, known for their exceptional thermal stability, lightweight and oxidative resistance, are highly desirable materials for TPS; nevertheless, their inherent anisotropy in thermal conductivity constrains the efficiency of in-plane heat transfer under severe thermal gradients. Herein, we developed an innovative CBCF composite impregnated with SiBCN–ZrO 2 aerogels (CBCF/SiBCN–ZrO 2 ), which establishes a synergistic architecture to enhance the efficiency of in-plane heat dissipation, thereby mitigating temperature gradients and improving thermal management. The precursor aerogel intended for the matrix was primarily investigated. The CBCF/SiBCN–ZrO 2 composite was synthesized through a solvothermal reaction following infiltration. Microscopic morphology analysis revealed that the aerogel matrix effectively encapsulated and filled the interior of the modified CBCF framework. The lightweight CBCF/SiBCN–ZrO 2 composite exhibited a density of 0.25–0.26 g/cm 3 , with compressive strengths of 2.82–3.19 MPa and 1.30–1.39 MPa in the in-plane (IP) and through-the-thickness (TTT) directions, respectively. The dual functionality of both thermal insulation and in-plane conduction was characterized and verified through quantitative thermal conductivity testing, as well as qualitative assessments of its insulation and in-plane heat‑leading properties. The sample with a single 0.2 mm-thick heat‑leading layer exhibited thermal conductivities of 29.35 W/(m·K) in the IP direction and 0.075 W/(m·K) in the TTT direction. This nearly 400-fold anisotropic difference endows the sample with highly efficient thermal management capabilities, potentially addressing the critical requirements for multifunctional TPS in aerospace applications.