Effect of ZrO2 morphology on the ablation resistance of carbon/carbon composites containing ZrC prepared by the carbothermal reduction reaction

• ZrC distribution in the C/C-ZrC composites was controlled by morphology of ZrO2.
• Dispersed submicron ZrC particles were got by reaction of ZrO2 whiskers and carbon.
• Dispersed submicron ZrC particles suppressed the oxidation of carbon.
• Dispersed submicron ZrC particles hindered the mechanical erosion of carbon.

Three types of carbon/carbon composites containing ZrC particles (C/C-ZrC) were prepared by the carbothermal reduction reaction of ZrO2 and carbon. ZrC distributed around the carbon fibers, among the fibers, and dispersed in the carbon matrix corresponding to the ZrO2 layer, particles, and whiskers in the carbon fiber preforms, respectively. The composite with ZrC dispersed in the carbon matrix showed the best ablation resistance. Dispersive distribution of the ZrC particles was helpful to form a continuously melting ZrO2 layer and this can prevent carbon from oxidizing and restrain the mechanical erosion of the composites.