Engineering Cf/ZrB2‐SiC‐Y2O3 for Thermal Structures of Hypersonic Vehicles with Excellent Long‐Term Ultrahigh Temperature Ablation Resistance

Abstract Ultrahigh temperature ceramic matrix composites (UHTCMCs) are critical for the development of high Mach reusable hypersonic vehicles. Although various materials are utilized as the thermal components of hypersonic vehicles, it is still challenging to meet the ultrahigh temperature ablation‐resistant and reusability. Herein, the Y 2 O 3 reinforced C f /ZrB 2 ‐SiC composites are designed, which demonstrates near‐zero damage under long‐term ablation at temperatures up to 2500 °C for ten cycles. Notably, the linear ablation rate of the composites (0.33 µm s −1 ) is over 24 times better than that of the conventional C f /C‐ZrC at 2500 °C (8.0 µm s −1 ). Moreover, the long‐term multi‐cycle ablation mechanisms of the composites are investigated with the assistance of DFT calculations. Especially, the size effect and the content of the Zr‐based crystals in the oxide layer fundamentally affect the stability of the oxide layer and the ablation properties. The ideal component and structure of the oxide layer for multi‐cycle ablation condition are put forward, which can be obtained by controlling the Y 2 O 3 /ZrB 2 mole ratio and establishing Y‐Si‐O – t ‐Zr 0.9 Y 0.1 O 1.95 core‐shell nano structure. This work proposes a new strategy for improving the long‐term multi‐cycle ablation resistance of UHTCMCs.