A rapid fabrication of C/C composites by a thermal gradient chemical vapor infiltration method with vaporized kerosene as a precursor

A thermal gradient, atmospheric pressure chemical vapor infiltration method with simultaneous vaporized kerosene as a precursor for rapid fabrication of C/C composites was studied. By this method, carbon felts (bulk density ∼0.2 g cm−3) were densified to C/C composites with density of 1.67 and 1.71 g cm−3 when prepared at 1050 and 1150 °C for 6 h, respectively. X-ray diffraction result indicates that the composites have a strong ability to graphitize and the higher deposition temperature leads to the increased graphitization degree. Polarized light microscope and scanning electron microscope images reveal that fibers of the composites prepared for 6 h are surrounded by ring-shaped pyrocarbon matrix with a thickness of ∼20 μm, and that the matrix is delaminated to 4–6 layer-like regions. The deposition process is analyzed by dividing the reactor into four regions associated with specific functions and the reasons for the rapid fabrication are proposed as the short convection and diffusion path for the precursor and the existing of thermal gradient across the preform.