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Fabrication of ZrB2 anti-oxidation coating on carbon/carbon composite surface by molten salt electrophoretic deposition.

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Title: Fabrication of ZrB2 anti-oxidation coating on carbon/carbon composite surface by molten salt electrophoretic deposition.
Authors: Yuan, Yong1 (AUTHOR), Qi, Wenjuan1 (AUTHOR), Xu, Junjie1 (AUTHOR), Ge, Chuntao1 (AUTHOR), Jin, Weiliang2 (AUTHOR), Zhang, Jun1 (AUTHOR), Xiao, Saijun1 (AUTHOR) jxddroc@126.com
Source: Journal of Materials Science. Jun2026, Vol. 61 Issue 23, p16347-16362. 16p.
Subjects: Electrophoretic deposition, Zirconium boride, Corrosion resistant materials, Carbon composites, Corrosion resistance, Oxidation, Nanoindentation, Mechanical behavior of materials
Abstract: To address the high-temperature oxidation of carbon/carbon (C/C) composites, this study employed a novel molten salt electrophoretic deposition (MS-EPD) technique to fabricate a zirconium diboride (ZrB2) anti-oxidation coating. Using ZrB2 nanoparticles synthesized in situ in molten salt as a precursor, a uniform and dense coating with a thickness of approximately 50 μm and good adhesion to the substrate was obtained at an optimized deposition voltage of 1.0 V. The coating exhibited excellent mechanical properties, with its nano-hardness and elastic modulus reaching as high as 35.8 and 510 GPa, respectively, and a critical adhesion load with the substrate of 10.8 N. This technique demonstrated high efficiency, with an average deposition rate of up to 0.865 μm/min. High-temperature oxidation tests revealed that the coating forms a ZrO2–B2O3 composite oxide layer above 973 K, effectively blocking oxygen ingress. The coating continued to provide effective protection for the substrate after isothermal oxidation at 1173 K in an air atmosphere for 5 h. This research confirms that MS-EPD is an efficient, feasible, and promising technique for preparing high-performance anti-oxidation coatings on C/C composites. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:To address the high-temperature oxidation of carbon/carbon (C/C) composites, this study employed a novel molten salt electrophoretic deposition (MS-EPD) technique to fabricate a zirconium diboride (ZrB2) anti-oxidation coating. Using ZrB2 nanoparticles synthesized in situ in molten salt as a precursor, a uniform and dense coating with a thickness of approximately 50 μm and good adhesion to the substrate was obtained at an optimized deposition voltage of 1.0 V. The coating exhibited excellent mechanical properties, with its nano-hardness and elastic modulus reaching as high as 35.8 and 510 GPa, respectively, and a critical adhesion load with the substrate of 10.8 N. This technique demonstrated high efficiency, with an average deposition rate of up to 0.865 μm/min. High-temperature oxidation tests revealed that the coating forms a ZrO2–B2O3 composite oxide layer above 973 K, effectively blocking oxygen ingress. The coating continued to provide effective protection for the substrate after isothermal oxidation at 1173 K in an air atmosphere for 5 h. This research confirms that MS-EPD is an efficient, feasible, and promising technique for preparing high-performance anti-oxidation coatings on C/C composites. [ABSTRACT FROM AUTHOR]
ISSN:00222461
DOI:10.1007/s10853-026-12843-4