Oxidation Behavior of Carbon Fibers in Ceramizable Phenolic Resin Matrix Composites at Elevated Temperatures

Carbon fiber fabric-reinforced phenolic resin composites are widely used as thermal protection materials for thermal protection systems in hypersonic vehicles and capsules. In this work, carbon fiber fabric-reinforced boron phenolic resin composites modified with MoSi₂ and B₄C were prepared via a compression molding technique. The high-temperature performance of the composites as well as the oxidation behavior of the carbon fibers was studied. The results indicate that the incorporation of B₄C improves the performance of composites at high temperatures. The residual weight rate of composites with 15 phr B₄C (BP-15) sufficiently increased from 23.03% to 32.91% compared with the composites without B₄C (BP-0). After being treated at 1400 °C for 15 min, the flexural strength of BP-15 increased by 17.79% compared with BP-0. Compared with BP-0, the line ablation rate and mass ablation rate of BP-15 were reduced by 53.96% and 1.56%, respectively. In addition, MoSi₂ and B₄C particles had a positive effect on the oxidation of carbon fibers in the composites. After treatment at 1400 °C, the diameter of the as-received carbon fiber was reduced by 31.68%, while the diameter of the carbon fiber in BP-0 and BP-15 decreased by 15.12% and 6.14%, respectively. At high temperatures, the liquid B₂O₃ from B₄C and MoSi₂-derived complex-phase ceramics (MoB, MoB₂, Mo₂C, Mo4.8Si₃C0.6) acted as an oxygen barrier, effectively mitigating the oxidation degree of the carbon fibers.