Influence of air plasma-sprayed YSZ coating on the thermal and ablation behaviour of SiC-modified carbon-phenolic composites for re-entry space vehicle applications

Abstract Thermal Protection Systems (TPS) with enhanced thermal and ablation resistance are crucial for space vehicle re-entry. Deposition of Thermal Barrier Coatings (TBCs) on the carbon-based composites, incorporated with ceramic fillers, offers superior performance for advanced aerospace applications. Hence, this present work develops a composite by reinforcing Resorcinol Phenol Formaldehyde Resin (PR) with Polyacrylonitrile (PAN)-based Carbon Fiber Fabric (Cf-PR) composites. The Silicon Carbide (SiC) is incorporated in several concentrations (0, 1, 3, and 5 wt%) followed by coating with 8 wt% of Yttria (Y 2 O 3 )-Stabilized Zirconia (YSZ) powder using Air Plasma Spray (APS). Thermal stability and ablation characteristics are assessed by Thermogravimetric Analysis (TGA) and the Oxyacetylene Torch Test (OAT) conducted at 400 W cm −2 for 60 s, respectively. The ablated surfaces’ phase composition and microstructure are analyzed using x-ray Diffraction (XRD), Energy Dispersive Spectroscopy (EDS) and Scanning Electron Microscopy (SEM). Analysis revealed that Cf-PR 3wt% SiC-YSZ coated composites exhibited enhanced thermal and ablation properties, making them strong candidates for advanced aerospace applications.