Oxidation resistance of a SiC–ZrB2 coating prepared by a novel pack cementation on SiC-coated graphite

In this study, a functionally graded SiC layer was prepared on a graphite substrate by a pack cementation method with Si, C, and Al2O3 powders. Then a SiC–ZrB2 coating was developed by an in situ reaction method through a novel pack cementation technique at 1873 K with Zr, Si, and B4C powders to improve the oxidation protection ability of SiC-coated graphite. The phase compositions, microstructure, and element distribution of the coating were identified by X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray spectroscopy, respectively. The isothermal oxidation test of the coated samples was accomplished at 1773 K in air for 10 h. According to the results, a 550-μm thick graded C–SiC layer was detected at the graphite–coating interface and a SiC–ZrB2 coating was formed on the first coating. The SiC–ZrB2 coating could efficiently enhance oxidation resistance of graphite with a mass gain of +1.1 %, as compared with a −1.2 % mass loss of the first step coating. The excellent protection ability of SiC–ZrB2 coating could be ascribed to the high thermally stable ZrSiO4.