Advances in ultra-high-temperature ceramic coatings with enhanced oxidation resistance for carbon-based composites

Xuanru Ren, Peipei Wang, Yuexing Chen, Wei Xie, Xiang Ji, Zhichao Shang, Chengshan Ji, Jun Zhao, Huiqun Liu, Guozheng Lv, Peizhong Feng

Extreme Materials ›› 2025, Vol. 1 ›› Issue (3) : 9-43.

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Extreme Materials ›› 2025, Vol. 1 ›› Issue (3) : 9-43. DOI: 10.1016/j.exm.2025.07.003

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Advances in ultra-high-temperature ceramic coatings with enhanced oxidation resistance for carbon-based composites

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• This review examines advances in oxidation-resistant coatings for C/C composites.

• Structural design strategies for enhanced oxidation resistance are summarized.

• Coating techniques and performance evaluation methods are systematically discussed.

• Insights into glass-phase self-healing under extreme thermal conditions are given.

• Future challenges and design principles for ultra-high-temp protection are outlined.

Abstract

Carbon-based composites are widely utilized in aerospace engines, thermal protection systems of hypersonic vehicles, and ultrahigh-temperature structural components, due to their lightweight nature, high strength, excellent mechanical properties, and thermal stability. However, the inherent susceptibility of carbon-based composites to high-temperature oxidation significantly limits their service life, highlighting the urgent need for the development of efficient oxidation-resistant barriers to enhance the long-term operational stability. In recent years, ultra-high temperature ceramic (UHTC) coatings have attracted considerable attention owing to their outstanding oxidation resistance. Nevertheless, such protective coatings still face critical challenges to hinder practical applications, including crack propagation, dynamic consumption instability of oxidation glass films, generation of oxidation holes and interfacial damage, which remain prevalent. In this work, a comprehensive overview of the research progress in UHTC coatings for carbon-based composites is provided, with particular emphasis on examining the influence of hierarchical structural design on oxidation resistance. Specifically, the role of advanced manufacturing techniques in optimizing microstructural stability and interfacial bonding strength is thoroughly discussed. Furthermore, the high-temperature oxidation protection mechanisms of UHTC coatings are examined, including strategies to optimize the composition of the oxidation glass film, stabilize the self-generated glass phase, and enhance densification of coating. In addition, various characterization methods are discussed for evaluating the oxidation resistance of the coatings, along with a systematic evaluation of stability under different service conditions. Finally, analysis of current technical challenges and unresolved issues, especially challenges and technical prospects regarding the field of oxidation-resistant coatings for carbon-based composites are discussed, while offering perspectives on future developments.

Key words

Ultra-high temperature ceramics / Carbon-based composite / Oxidation resistance / Coatings / High oxygen blocking properties

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Xuanru Ren, Peipei Wang, Yuexing Chen, 等. [J]. Extreme Materials. 2025, 1(3): 9-43 https://doi.org/10.1016/j.exm.2025.07.003
Xuanru Ren, Peipei Wang, Yuexing Chen, et al. Advances in ultra-high-temperature ceramic coatings with enhanced oxidation resistance for carbon-based composites[J]. Extreme Materials. 2025, 1(3): 9-43 https://doi.org/10.1016/j.exm.2025.07.003

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This work has been supported by the National Natural Science Foundation of China (52261135546, 52272055, 52302047, 52302050), the Key Research and Development Project of Henan Province (241111232600), the Joint Fund of Henan Province Science and Technology R&D Program (225200810031, 235200810095, 225200810002), the Key Research Project Plan for Higher Education Institutions of Henan Province (24A430042), the International Science and Technology Cooperation Project of Henan Province (252102521081), the High-level Talent Research Start-up Project Funding of Henan Academy of Sciences (Project No. 242021135), Yuexing Chen would like to acknowledge the financial support from the Postgraduate Innovation Project of Henan Academy of Sciences (243321013).


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