Integrated process for eco-friendly synthesis and coating of ZrB2 onto carbon fiber substrates

In aerospace engineering, the demand for lightweight materials with superior strength and endurance drives the search for advanced composites. Carbon fiber composites offer exceptional strength-to-weight ratios but are vulnerable to high-temperature oxidation. To address this, protective coatings are crucial. Zirconium diboride (ZrB₂) shows promise due to its high melting point and stability but faces challenges in application. Here, we propose a sustainable solution-based method using gum arabic, a natural polysaccharide, as a precursor to coat carbon fibers followed by pyrolysis to form ZrB₂. Our technique simplifies production while enhancing coating effectiveness and adhesion. X-ray diffraction and microscopy analyses confirm successful ZrB₂ formation and uniform coating. Thermal analysis demonstrates improved oxidative stability compared to pristine carbon fibers. This eco-friendly approach presents a novel avenue for aerospace materials synthesis, offering enhanced performance and sustainability. The study underscores the potential of solution-based techniques and natural precursors in advancing composite materials for extreme environments.