Advancements in Design and Manufacture of High-Performance Modified Carbon/Carbon Composites for Extreme Aerospace Environments: A Comprehensive Review

The demand for materials that can operate reliably in extreme environments, including rocket nozzles, re-entry heat shields, sharp leading edges, high-velocity impact, and high-temperature energy systems, continue to drive advances in thermal–structural materials. Carbon/Carbon composites remain a leading baseline because of their low density, high-temperature mechanical retention in inert atmospheres, and excellent thermal-shock tolerance. However, long-term durability is constrained by rapid oxidation in air at elevated temperatures, limited fracture toughness and elastic modulus in many architectures, and high manufacturing cost driven by multi-cycle densification and stringent quality assurance. Consequently, contemporary strategies increasingly rely on modifying Carbon/Carbon composites with ultra-high-temperature ceramics and adopting accelerated or simplified manufacturing routes. This review synthesizes recent progress in the design, manufacture, and application of high-performance modified Carbon/Carbon composite systems for extreme aerospace environments, emphasizing composition/architecture selection, oxidation, and ablation protection, toughening concepts, and cost-aware densification. Because extreme environments performance is governed by coupled aerothermal loading, gas–surface chemistry, internal transport, recession, and thermomechanical response, the review also consolidates the multiscale modeling and software toolchains increasingly used to size thermal-protection systems, interpret experiments, and guide down-selection. Key challenges and future directions are further discussed for reusable materials and validated performances beyond ~2000 °C.