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A thick ZrC layer was successfully coated on top of a SiC buffer layer on carbon/carbon (C/C) composites by vacuum plasma spray (VPS) technology to improve the ablation resistance of the C/C composites. An optimal ZrC coating condition was determined by controlling the discharge current. The ZrC layers were more than 70 µm thick and were rapidly coated under all spraying conditions. The ablation resistance and the oxidation resistance of the coated layer were evaluated in supersonic flames at a temperature exceeding 2000 °C. The mass and linear ablation rate of the ZrC-coated C/C composites increased by 2.7% and 0.4%, respectively. During flame exposure, no recession was observed in the C/C composite. It was demonstrated that the ZrC coating layer can fully protect the C/C composites from oxidation and ablation.

Characteristics of ZrC Barrier Coating on SiC-Coated Carbon/Carbon Composite Developed by Thermal Spray Process