Conventional
carbon fiber felt-reinforced aerogel composites are
often used as lightweight thermal protection systems (TPSs) for aerospace
craft. However, due to their poor oxidation resistance, they have
gradually failed to handle increasingly harsh thermal environments.
In this work, a nanoscale composite coating interface of SiC-ZrC ceramic
precursor is first constructed on the fiber surface. Subsequently,
using the coated fiber felt as a three-dimensional skeleton and through
polymerization-induced phase separation, an aerogel composite with
excellent thermal protection in extreme thermal environments is prepared.
Owing to the in situ ceramization of this nanoscale interface at ultrahigh
temperatures, the back temperature of the 12 mm thick aerogel is
only 147 °C after exposure to an oxyacetylene flame at 1950 °C
for 70 s. Meanwhile, the central region of the aerogel recedes by
only 7%. Not only does this work provide a way to enhance aerogels
by constructing a self-ceramizable nanoscale interface it is also
expected that the developed aerogel composite can be applied in the
ultrahigh-temperature thermal protection of future aerospace craft.