Crack Evolution and Oxidation Failure Mechanism of a SiC-Ceramic Coating Reactively Sintered on Carbon/Carbon Composites

A SiC ceramic coating was prepared on carbon/carbon composites by pack cementation. The phase composition and microstructure of the coated specimens were characterized using X-ray diffraction instrument and scanning electron microscope. The results showed that the mass-loss percentage of the coated specimen was 9.5% after being oxidized for 20 h. The oxidation failure of the SiC ceramic coating at 1773 K was analysed by non-destructive X-ray computed tomography. The effective self-healing of cracks with widths below 12.7 μm introduced during the coating preparation process and generated while the specimens cooled down from the high oxidation temperature prevented the oxidation of carbon/carbon composites. X-ray computed tomography was used to obtain three-dimensional images revealing internal damage caused by spallation and open holes on the coating. Stress induced by heating and cooling caused the formation, growth and coalescence of cracks, which in turn led to exfoliation of the coating and subsequent failure of oxidation protection.