Effects of carbon matrix on microstructure and properties of 3-D C/ZrC composites prepared by reactive melt infiltration

Three-dimensional braided carbon fiber-reinforced ZrC matrix composites, 3-D C/ZrC, were fabricated by reactive melt infiltration process at 1200 °C. Phenolic resin and asphalt were used as carbon precursors, and the effects of carbon matrix on microstructure and properties of the 3-D C/ZrC composites were investigated. The composites fabricated with asphalt showed a higher ZrC yield of 37.5±1.0 vol% and better anti-ablative properties, with a mass loss rate of 0.8±0.3 mg s−1 and a linear recession rate of 0.0006±0.0002 mm s−1. However, the use of phenolic resin could provide better mechanical properties of the obtained composites, including a flexural strength of 285.4±9.7 MPa, an elastic modulus of 76.2±4.0 GPa and a fracture toughness of 8.9±0.8 MPa m1/2. The main reason for the superior mechanical properties is the preservation of carbon fiber bundles in the phenolic resin based composites.