Synthesis and structure–property relationships of a new family of layered carbides in Zr-Al(Si)-C and Hf-Al(Si)-C systems

The layered ternary and quaternary carbides in Zr-Al(Si)-C and Hf-Al(Si)-C systems with general formulae of (TC)nAl3C2, (TC)nAl4C3 and (TC)n[Al(Si)]4C3 (where T = Zr or Hf, n = 1, 2, 3…) have attracted increasing attentions due to their fascinating properties such as high specific stiffness, high strength and fracture toughness, refractory, machinability by electrical discharge method, thermal shock resistance, as well as high-temperature and ultrahigh-temperature oxidation resistance. The combination of these properties makes them promising as structural components or coatings for high- and ultrahigh-temperature applications. In this review, the progresses on processing, and structure–property relationships of the novel layered carbides are comprehensively outlined. The crystal structure characteristics are introduced first. Then, methods for processing powders and bulk samples are summarized. The third section focuses on the multi-scale structure–property relationships. Finally, the potential applications and further trends in tailoring the properties and developing low cost processing methods are highlighted.