Oxidation-Protection Methodology for Long-Term use of Carbon-Carbon Fiber-Matrix Composites in Oxidizing Ambients

Abstract

A methodology is described for protecting Carbon-Carbon fiber-matrix composite (C-C) components from oxidation for extended use in oxidizing ambients for lifetimes of the order of 10,000 hours, from room temperature to 650°C. This time-temperature profile is relevant to applications such as airborne heat exchangers. Weight changes of oxidation-protected, pitch-fiber based C-C coupons in flowing dry air at 650°C are presented. Two types of external protective approaches are compared: (a) multi-phase, borophosphate-based fluidizing overseal coatings applied directly to C-C, and (b) the same overseal coatings applied to CVD SiOxCy coated C-C. The latter, dual-coating approach provides an effective engineering solution for the above temperature-time profile and is particularly applicable to thin (0.1–3 mm thick), complex-shaped articles. The behavior of inert substrates (oxidized silicon) with the same overseal coatings is compared to the behavior of the C-C substrates. This approach can be applied with optional modifications to suit other environmental conditions, and other carbon-containing materials, such as carbon foams and C-SiC composites.