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Effects of nano-ZrSi2 on thermal stability of phenolic resin and thermal reusability of quartz–phenolic composites

  • Jie Ding , Yingluo Zhuang , Minxian Shi EMAIL logo , Zhixiong Huang , Yan Qin , Yan Li and Cunku Wang
Published/Copyright: November 11, 2022
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Abstract

In this article, nano-ZrSi2-modified phenolic (Ph) resin and nano-ZrSi2-modified quartz–phenolic (Q–Ph) composites are, respectively, prepared by resin casting and compression molding. The effect of nano-ZrSi2 on the thermal stability of Ph resin and the role of nano-ZrSi2 on the thermal reusability of Q–Ph composites are investigated by multiple thermal gravimetric analyses and mechanical tests. The strengthening mechanism of nano-ZrSi2 modification is investigated by the evolution of microstructure. The results show that the addition of nano-ZrSi2 enhances the thermal stability of Ph resin under repeated heating at 1,200°C in air. The enhancement in thermal stability of resin exhibits a positive effect on improving the thermal reusability of composites. Within the range of 20 repeated heating times, the flexural strength of nano-ZrSi2-modified composites is above 16.01 MPa, which is 163.8% higher than that of unmodified composites. The strengthening mechanism of nano-ZrSi2 is mainly in the inhibition of thermal oxidation and the reduction of microstructural defects during the repeated thermal environment.

1 Introduction

With the development of aerospace technology, especially hypersonic vehicle technology, the requirements for advanced thermal protection materials are constantly increasing [1,2]. Hypersonic vehicle has the characteristics of high velocity, long range, and quick response [1]. These require thermal protection materials to have corresponding characteristics, such as high-temperature resistance, low density, high strength, and manufacturability [3]. In addition, thermal protection materials need to be reusable to meet the requirements, such as air-breathing hypersonic vehicle that can not only cruise in the atmosphere at high speed but also pass through the atmosphere as a space transportation vehicle [1]. This also requires thermal protection materials that are resistant to oxidation and reusable in high-temperature oxygen-containing environments.

Typical inorganic nonmetallic reusable thermal protection materials mainly include ceramic matrix composites, C/C, C/SiC, SiC/SiC, and other materials, which have high thermal stability and chemical inertness [4,5]. However, the disadvantage of these materials is the complex preparation process. Reusable thermal protection materials require innovation. Adding nanoparticles can effectively improve the properties of materials [6,7], and many scholars have done related research in this regard. Eslami et al. [8] investigated the thermal, mechanical, and ablation properties of carbon fiber/phenolic (Ph) composites filled with multiwall carbon nanotubes (MWCNTs). The thermal stability and flexural properties of the nanocomposites increased by increasing the content of MWCNTs (wt% ≤1). MWCNTs in the composite formed a strong network char layer without any cracks or openings. Park et al. [9] studied the mechanical and thermal properties of graphite oxide (GO)–Ph composites with different sizes of GO. They concluded that the composites with larger sizes of GO particles typically exhibited better mechanical properties. The incorporation of GO particles significantly accelerated the crystallization process of the Ph resin matrix, and the thermal stability of composites was improved. Srikanth et al. [10] manufactured the high ablation resistance rayon-based carbon-fabric/Ph composites using nano-SiO2 powder as a filler material. Nano-silica-filled composite exhibited higher ablation resistance when compared to the unfilled composite. Asaro et al. [11] used mesoporous SiO2 particles as reinforcement of a Ph resin to develop new ablative materials. They concluded that the composite with 20% silica particles achieved the best performance because the mesoporous structure was responsible for the improved ablation performance. Duan et al. [12] studied the effects of borosilicate glass and polycarbosilane on the oxidation and ablation behaviors of carbon fiber/Ph resin composites. They found that the fillers changed the oxidation mechanism of the composite at temperatures above 1,000°C. This modification improved the strength of the composite after oxidation. Wang et al. [13] evaluated the effects of zirconium carbide content on thermal stability and ablation properties of carbon/Ph composites. They showed that increasing ZrC content could lead to an evident increase in char yield but an observable reduction in linear ablation rates and back-face temperatures because of the formation of the ZrO2 layer on the ablation surface. Chen et al. [14] introduced ZrB2 particles into Ph resin and prepared modified carbon–phenolic (C–Ph) composites with this resin as a matrix. ZrB2 could improve the thermal stability of Ph resin. The formation of ZrO2 and B2O3 could notably improve the ablation resistance of C–Ph composites during the ablation process.

In our previous study, ZrSi2 particles were used as the filler material in Ph resin and C–Ph composites [15,16]. The thermal stability of ZrSi2 to Ph resin under inert gas and the ablation resistance of ZrSi2 to C–Ph composite under oxyacetylene flame have been deeply studied and discussed. The introduced ZrSi2 particles reacted with pyrolytic volatiles derived from Ph resin, which could increase the char yield of Ph resin. The increased char yield, as well as the formations of SiO2 and ZrO2, could contribute to the improvement of ablation resistance for C–Ph composites. In addition, TiB2 particles were used as the filler material in Ph resin and C–Ph composites [17]. The effect of TiB2 on the thermal stability of Ph and the role of TiB2 on the high-temperature mechanical property of C–Ph composites have been investigated. At high temperatures, TiB2 particles reacted with oxygen or oxygen-containing molecules released by Ph pyrolysis. The residue of Ph after pyrolysis coated with glassy B2O3 and ceramic particles could form a new compact matrix. The new compact matrix and well-bonded interface ensured the improved mechanical properties of TiB2-modified C–Ph composites at high temperatures.

All these studies showed that the non-oxide ceramic particle-modified C–Ph composites performed well in single-use thermal environments. However, for the thermal protection requirements of reusable hypersonic vehicles, the thermal stability and thermal reusability of such materials under repeated heating have not been investigated.

In this article, we prepare modified Ph resin-based composites by nano-ZrSi2 particles as additives and quartz fibers as reinforcements. The aims of this article are: (i) to study the effect of nano-ZrSi2 on the thermal stability of Ph under repeated heating; (ii) to investigate the thermal reusability of nano-ZrSi2-modified quartz–phenolic (Z/Q–Ph) composites; and (iii) to study the microstructure evolution to understand the strengthening mechanism of nano-ZrSi2 during repeated thermal environment.

2 Experimental

2.1 Materials

Boron phenolic resin (Ph) solid content ≥ 60%, Shanxi Taihang Fire Resistant Polymer Co., Ltd. Quartz fiber fabric, surface density 840 ± 42 g/m2, Wuhan Xin Youtai Optoelectronic Technology Co., Ltd. Nano-ZrSi2 particles, purity ≥95%, Shanghai Aladdin Biochemical Technology Co., Ltd, particle size distribution, and micromorphology as shown in Figures 1 and 2.

Figure 1 
                  Particle size distribution of nano-ZrSi2 particles.
Figure 1

Particle size distribution of nano-ZrSi2 particles.

Figure 2 
                  Scanning electron micrograph of nano-ZrSi2 particles.
Figure 2

Scanning electron micrograph of nano-ZrSi2 particles.

2.2 Sample preparation

2.2.1 Fabrication process of Z/Ph resin

The preparation of nano-ZrSi2-modified phenolic (Z/Ph) resin was divided into two steps: glue preparation and resin casting process. First, nano-ZrSi2 particles were introduced into the Ph resin in the mass fraction of 60 wt% by mechanical mixing for 30 min. Then, the mixture was poured into a thin mold and cured in an oven at 180°C for 3 h to obtain nano-ZrSi2 modified Ph resin. The pure Ph resin was also fabricated into a sub-sample with the same fabrication process.

The two resin samples were subjected to repeated heat treatment at 1,200°C for 0–20 times. The repeated heat treatment process was as follows: put the sample into a muffle furnace at 1,200°C and the single heating time is 10 min. The whole process environment is an air atmosphere. The number of heat treatments is used as a suffix for the sample marking. For example, unheated modified Ph resin is marked as Z/Ph-0, unheated Ph resin is marked as Ph-0, modified Ph resin heated 20 times is marked as Z/Ph-20, and Ph resin heated 20 times is marked as Ph-20.

2.2.2 Fabrication process of Z/Q–Ph composite

The preparation of Z/Q–Ph composites was divided into three steps: glue preparation, prepreg preparation, and compression molding. First, the resin solution was prepared according to the proportion of Z/Ph resin. Then, the resin solution was painted on the quartz fiber fabric in a mass rate of 2:1, and the fabric was dried at room temperature to form a prepreg. Finally, the prepregs were laminated and compressed in a mold to form the Z/Q–Ph composite. The pure quartz–phenolic (Q–Ph) composite was also fabricated into a sub-sample with the same fabrication process. The curing process of all samples is shown in Figure 3.

Figure 3 
                     Curing curves of molding process.
Figure 3

Curing curves of molding process.

The two composite samples were also subjected to repeated heat treatment at 1,200°C for 0–20 times. The repeated heat treatment process of composites is the same as that of resins. The number of heat treatments is used as a suffix for the sample marking. For example, unheated Z/Q–Ph composite material is marked as Z/Q–Ph-0, unheated Q–Ph composite material is marked as Q–Ph-0, modified Z/Q–Ph composite material heated 20 times is marked as Z/Ph-20, and Q–Ph composite material heated 20 times is marked as Q–Ph-20.

2.3 Characterization

The thermal stabilities of Ph resin and Z/Ph resin were characterized by thermal analyzer (model DSC8500). Thermal gravimetric tests were in an atmosphere of air with a heating rate of 20.0°C/min and a temperature range of 30–1,200°C. The mechanical properties of Q–Ph composites and Z/Q–Ph composites after different heating times were investigated by a universal machine (model Instron-1341). The flexural strength of the sample was tested concerning the standard GB/T1449-2005, and the loading rate was 2 mm/min. The microscopic morphologies of resins and composites after different heating times were tested using a scanning electron microscope (SEM) (model JSM-5610LV).

3 Results and discussion

3.1 Thermal stability of resin

Residual weight is an important indicator to measure the thermal stability of resin. Generally speaking, higher residual weight of resin means better thermal stability [18,19,20]. The thermal stabilities of pure Ph resin and Z/Ph resin in the air were characterized by thermogravimetric (TG) analysis. Figure 4 compares the TG curves of Ph resin and Z/Ph resin.

Figure 4 
                  TG curves of Ph resin and Z/Ph resin.
Figure 4

TG curves of Ph resin and Z/Ph resin.

As seen from the curve of Ph resin in Figure 4, the oxidative decomposition process of Ph resin is divided into three stages [21]. In the first stage of 30–350°C, the weight loss rate of Ph resin is 6.6%. It can be known that the weight loss of this part is not the decomposition of Ph, but the post-curing of Ph [22]. In the second stage of 350–850°C, the Ph resin shows a significant weight loss, reaching 76.3% by weight, which is due to the thermal oxidation of Ph resin [23]. In the third stage of 850–1,200°C, the weight loss rate of Ph resin is 11.8%, which is mainly caused by the further pyrolysis of the benzene ring [24]. At 1,200°C, the residual weight rate of Ph resin is 5.3%. Unlike Ph resin, the TG curve of Z/Ph resin remains almost horizontal. Moreover, the weight of Z/Ph resin even increases slightly above 1,000°C, and the residual weight rate of Z/Ph resin at 1,200°C is 100.7%. This is mainly due to the oxidation reaction of nano-ZrSi2 itself, which increases the residual weight of Z/Ph resin. In addition, oxidation products of nano-ZrSi2 have protective effects on the Ph resin, thereby inhibiting the thermal oxidation reaction of Ph resin during the heating process [25].

To further study the effect of nano-ZrSi2 on the thermal stability of Ph under repeated heating, the Z/Ph resin samples treated with different heating times are measured again by TG. Figure 5 shows the TG curves of Z/Ph resin after 0, 1, 4, and 8 heating times.

Figure 5 
                  TG curves of Z/Ph resins after different heating times.
Figure 5

TG curves of Z/Ph resins after different heating times.

As shown in Figure 5, the TG curves of Z/Ph resin after different heating times tend to be stable gradually. The weight change process of Z/Ph resin is mainly divided into two stages. In the first stage of 30–1,000°C, the residual weights of Z/Ph-0, Z/Ph-1, Z/Ph-4, and Z/Ph-8 have various changes. At 1,000°C, the residual weight rates of above four samples are 99, 101, 98.9, and 99.3%, respectively. Notably, Z/Ph-1 shows no weight loss but weight gain. This is because one heating time is relatively short. Nano-ZrSi2 particles are not sufficiently oxidized, and thus, weight gain occurs. With the increase in heating times, nano-ZrSi2 particles are fully oxidized at high temperature [26,27,28], and the TG curves of samples gradually maintain a horizontal state. In the second stage of 1,000–1,200°C, the residual weights of four samples increase slightly, which is the result of the nanoparticles oxidation at elevated temperature. At 1,200°C, the residual weight rates of four samples are 100.7, 103.4, 101.4, and 100.1%. In both stages, the change range of residual weight rates is within 4%. This shows that the modified Ph resin exhibits excellent thermal reusability in the range below 1,200°C.

3.2 Microstructural evolution of resin

The microstructural evolution of resin under repeated thermal environment is investigated by SEM. Figure 6 shows the microstructures of Ph resin and Z/Ph resin after different heating times at 1,200°C.

Figure 6 
                  Micromorphology of Ph resin and Z/Ph resin after different heating times (a) Ph-0, (b) Ph-1, (c) Z/Ph-0, (d) Z/Ph-1, (e) Z/Ph-4, and (f) Z/Ph-8.
Figure 6

Micromorphology of Ph resin and Z/Ph resin after different heating times (a) Ph-0, (b) Ph-1, (c) Z/Ph-0, (d) Z/Ph-1, (e) Z/Ph-4, and (f) Z/Ph-8.

The microstructure of Ph resin is shown in Figure 6(a), and that after 1 heating at 1,200°C is shown in Figure 6(b). As seen in Figure 6(a) and (b), the resin surface has evolved from defect free to many voids, cracks, and other defects. It is well known that thermal oxidation of carbon materials starts at 450°C, and Ph resin is easily oxidized and destroyed in high-temperature air environment [29,30,31,32,33]. Therefore, the thermal degradation of Ph resin at 1,200°C is serious.

The microstructure of cured Z/Ph resin is shown in Figure 6(c), and those after 1, 4, and 8 heating times at 1,200°C are shown in Figure 6(d)–(f), respectively. As shown in Figure 6(c), nanoparticles are relatively uniformly dispersed in the modified resin, and the surface of modified resin has almost no defects. As shown in Figure 6(d), the nano-ZrSi2-modified resin is transformed into ceramics with layered structure after 1 heating. Due to the ceramization of modified resin, the surface defects of Z/Ph resin have been greatly reduced compared with those of heated Ph resin under the same condition. As shown in Figure 6(e), a few voids appear on the surface of Z/Ph resin after 4 heating times. However, there are no defects, such as cracking and large-area voids like heated Ph resin after heating. As shown in Figure 6(f), the compactness of sheet structure ceramic is improved, and the surface has few voids. The surface after 8 heating times has a healing phenomenon compared with the surface after 4 heating times.

With the increase in heating times, the surface of Z/Ph resin undergoes an evolution process from relatively dense to defective and then to relatively dense. The surfaces of all heated Z/Ph resin do not have defects, such as cracks and large-sized voids on the surface of heated Ph resin. Nano-ZrSi2 particles induce the ceramization of modified resin during heating, which plays a good role in the microstructure protection of Ph resin under high temperature and repeated high-temperature heating.

3.3 Thermal reusability of composites

To explore the thermal reusability of composites, the mechanical properties of samples after different heating times are tested. Composite samples are put into a furnace at 1,200°C for high-temperature treatment for 1, 2, 4, 6, 8, 10, 12, 16, 18, and 20 times. Each heating time is 10 min. After heat treatment, the flexural strength of each composite sample is tested, and the results are shown in Figure 7.

Figure 7 
                  Mechanical properties of Q–Ph composites and Z/Q–Ph composites after different heating times.
Figure 7

Mechanical properties of Q–Ph composites and Z/Q–Ph composites after different heating times.

After 1 heating, the flexural strength of Q–Ph composites is 9.87 MPa. With the increase in heating times, the flexural strength of Q–Ph composites decreases gradually. Although between 12 and 16 times, the flexural strength of Q–Ph composites recovers slightly. In the range of 1–20 times of heating, the flexural strength of Q–Ph composites shows a downward trend in general, and the lowest value of flexural strength appears after 20 times of heating, which is only 6.07 MPa.

The flexural strength of Q–Ph composites increases significantly after nano-ZrSi2 modification. After 1 heating, the flexural strength of the Z/Q–Ph composites is 20.04 MPa, which is 103.04% higher than that of Q–Ph composites under the same condition. With the increase in heating times, the flexural strength of Z/Q–Ph composites first decreases, then increases, and finally stabilizes overall. In the range of 1–20 times of heating, the lowest flexural strength of Z/Q–Ph composites appears after 4 times of heating, and its value is 16.01 MPa. After 20 times of heating, the flexural strength of Z/Q–Ph composites is 17.08 MPa.

In the range of 20 repeated heating, the flexural strength of Q–Ph composites is 6.08–9.87 MPa, while that of Z/Q–Ph composites is 16.01–20.04 MPa. Calculated at the lowest value, the flexural strength of Z/Q–Ph composites is 163.8% higher than that of pure Q–Ph composites. It can be concluded that the mechanical properties of Q–Ph composites after heating at 1,200°C are effectively improved with the addition of nano-ZrSi2. And the mechanical properties of Z/Q–Ph composites do not decrease significantly after repeated heating.

3.4 Enhancement mechanism of nano-ZrSi2 on composites

To explore the strengthening mechanism of nano-ZrSi2 on the heated composites, macromorphology, micromorphology, and element distribution of composites are studied. Photographs of Q–Ph samples and Z/Q–Ph samples after different heating times are shown in Figure 8.

Figure 8 
                  Photographs of Q–Ph composites and Z/Q–Ph composites after different heating times.
Figure 8

Photographs of Q–Ph composites and Z/Q–Ph composites after different heating times.

As shown in the photographs of Q–Ph composites, the surface of Q–Ph composites changes from the yellow of Ph resin to the white of quartz fibers with the increase of heating times. Due to the high-temperature oxidation of Ph resin, almost no residual Ph resin can be seen on the surface, and only the quartz fibers are exposed. As shown in the photographs of Z/Q–Ph composites, the surface of Z/Q–Ph composites changes slowly from the black of modified resin to a dark gray like a ceramic with the increase in heating times. Due to the protection of nano-ZrSi2, the surface of appears firm without exposed white fibers.

The cross-sectional microstructure of heated composites and the elemental distribution of typical area are shown in Figure 9.

Figure 9 
                  Cross-sectional micromorphology of heated composites. (a) Q–Ph-4, (b) Z/Q–Ph-4, (c) Z/Q–Ph-8, and (d) ceramic layer EDS of Z/Q–Ph-8.
Figure 9

Cross-sectional micromorphology of heated composites. (a) Q–Ph-4, (b) Z/Q–Ph-4, (c) Z/Q–Ph-8, and (d) ceramic layer EDS of Z/Q–Ph-8.

As shown in Figure 9(a), large voids and loose fiber bundles appear on the cross-section of Q–Ph-4 composites. The generation of such defects is due to the thermal oxidation of Ph resin matrix. During the repeated thermal oxidation, the matrix has been exhausted, and the fibers on the cross-section are not bound together. As shown in Figure 9(b), the defects on the cross-section of Z/Q–Ph-4 composites are greatly reduced. No obvious large voids are seen in Figure 9(b), and the fibers are bound firmly with the generated ceramic matrix. As shown in Figure 9(c), the dense ceramic matrix can be clearly observed on the cross-section of Z/Q–Ph-8 composites. As shown in Figure 9(d), elements B, C, O, Si, and Zr exist in the EDS analysis of the ceramic matrix. Notably, the molar ratio of O to Si and Zr is approximately equal to 2. It can be considered that nano-ZrSi2 particles are oxidized to form SiO2 and ZrO2 with heating under air atmosphere, which has been proved in previous studies [15,16]. That is, the ceramic matrix mainly composed of SiO2, ZrO2, C, and B is formed in an air atmosphere at 1,200°C and is stable during the repeated heating process.

The strengthening mechanism of nano-ZrSi2 on the heated composites can be analyzed as follows: without the introduction of nano-ZrSi2, pure Ph resin matrix is easy to be oxidized and eroded during heating, which seriously damages the interface of heated Q–Ph composites. When the heated sample is under load, it can only be supported by the quartz fibers alone, without the assistance of the matrix and the effect of interfacial stress transfer. Thus, the heated Q–Ph composites have very low mechanical properties. With the introduction of nano-ZrSi2, nanoparticles inhibit the oxidation of Ph resin matrix through self-oxidation at high temperatures. After 1 heating, the modified Ph resin matrix is transformed into a ceramic matrix containing oxidation products of nanoparticles and residual products of resin, and the carbon in the resin is well preserved. The ceramic matrix holds the fibers firmly in place and binds the quartz fibers together. When the heated Z/Q–Ph composite material is under load, both the fibers and the matrix bear the stress, with the quartz fibers as the main and the ceramic matrix as the auxiliary. The tight interfacial bond ensures the transfer of stress between the fibers and the matrix. This results in the improved mechanical properties of heated Z/Q–Ph composites. Moreover, the ceramic matrix is stable at high temperatures, which ensures that the load-bearing state of modified composites is not affected with the increase in heating times. Therefore, Z/Q–Ph composites exhibit significant mechanical properties under repeated heating environments.

4 Conclusion

Z/Q–Ph composites are prepared with Z/Ph resin as matrix and quartz fiber as reinforcement. The thermal stability of resin is characterized by multiple TG analyses, and the thermal reusability of composites is characterized by multiple mechanical tests. Their microstructural evolution is characterized by SEM. The main conclusions are as follows:

  1. The introduction of nano-ZrSi2 significantly improves the thermal stability of Ph resin in air. At 1,200°C, the residual weight rate of Z/Ph resin is 100.7%, while that of Ph resin is only 5.3%. And Z/Ph resin shows excellent thermal stability under repeated heating. In the range of eight repeated heating, Z/Ph resin shows a small change range of residual weight rates, all within 4%.

  2. The introduction of nano-ZrSi2 significantly improves the flexural strength of Q–Ph composites under repeated heating environment. In the range of 20 repeated heating, the flexural strength of Z/Q–Ph composites is above 16.01 MPa. Calculated at the lowest value, the flexural strength of Z/Q–Ph composites is 163.8% higher than that of pure Q–Ph composites. Z/Q–Ph composites have excellent thermal reusability.

  3. The introduction of nano-ZrSi2 significantly reduces the microstructural defects of all heated samples. In addition, Z/Ph resin matrix can be transformed into a new ceramic matrix after heating in air. The ceramic matrix is relatively stable during repeated heating, which provides the basis for the thermal stability of resin and the thermal reusability of composites under repeated thermal environment.


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  1. Funding information: Financial support was received from the Fundamental Research Funds for the Central Universities, China (WUT: 2021III003XZ).

  2. Author contributions: All authors have accepted responsibility for the entire content of this article and approved its submission.

  3. Conflict of interest: The authors state no conflict of interest.

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Received: 2022-03-16
Revised: 2022-04-30
Accepted: 2022-05-18
Published Online: 2022-11-11

© 2022 Jie Ding et al., published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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