Novel Synthesis and Characterization of High Quality Silicon Carbide Coatings on Carbon Fibers

Carbon fibers were coated with silicon carbide (SiC) by partially reacting with silicon (Si) powders in a NaCl-based salt for 4 h at 1200°C–1250°C in Ar, and characterized by using X-ray diffraction (XRD), scanning electron microscopy (SEM), atomic force microscopy (AFM), and energy dispersive X-ray (EDX) analysis. At 1200°C, almost no SiC was formed, whereas at 1250°C Si completely reacted to form SiC coatings on carbon fibers. The molten salt medium is believed to facilitate the dissolution and diffusion of Si and thus the SiC coating formation. The SiC coating thickness could be readily tailored by simply adjusting the Si/C ratio. To illustrate this, two different Si/C weight ratios (1/10 and 1/5) were used, respectively, to prepare a “thick” (300–350 nm) coating and a “thin” (~130 nm) coating. Both coatings were found to be continuous, homogeneous, and crack free.

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