Nano-silica modified lightweight and high-toughness carbon fiber/phenolic ablator with excellent thermal insulation and ablation performance

Lightweight and high-toughness carbon fiber/phenolic ablator (CFPA) is required as the Thermal Protection System (TPS) material of aerospace vehicles for next-generation space missions. To improve the ablative properties, silica sol with good particle size distribution prepared using tetramethoxysilane (TMOS) was blended with natural rubber latex and deposited onto carbon fiber felt, which was then integrated with phenolic aerogel matrix, introducing nano-silica into the framework of CFPA. The modified CFPA with a low density of 0.28–0.31 g/cm3 exhibits strain-in-fracture as high as 31.2% and thermal conductivity as low as 0.054 W/(m∙K). Furthermore, a trace amount of nano-silica could effectively protect CFPA from erosion of oxidizing atmosphere in different high-temperature environments. The oxyacetylene ablation test of 3000 °C for 20 s shows a mass ablation rate of 0.0225 g/s, a linear ablation rate of 0.209 mm/s for the modified CFPA, which are 9.64% and 24.82% lower than the unmodified one. Besides, the long-time butane ablation test of 1200 °C for 200 s shows an insignificant recession with mass and linear ablation rate of 0.079 g/s and 0.039 mm/s, 16.84% and 13.33% lower than the unmodified one. Meanwhile, the fixed thermocouple in the test also demonstrates a good thermal insulation performance with a low peak back-face temperature of 207.7 °C, 12.25% lower than the unmodified one. Therefore, the nano-silica modified CFPA with excellent overall performance presents promising prospects in high-temperature aerospace applications.