Effect of carbon fiber crystallite size on the formation of hafnium carbide coating and the mechanism of the reaction of hafnium with carbon fibers

The effect of carbon source crystallite size on the formation of hafnium carbide (HfC) coating was investigated via direct reaction of hafnium powders with mesophase pitch-based carbon fibers (CFs) heat-treated at various temperatures. X-ray diffraction, scanning electron microscopy and energy dispersive X-ray spectroscopy analyses reveal that uniform and dense HfC coatings are preferentially formed on CFs containing larger and more ordered graphite crystallites. The carbide synthesis temperature and the sizes of crystallites in the CFs have a remarkable influence on the integrity and thickness of the coatings. The formation the HfC coatings can be attributed to the surface diffusion of hafnium and the bi-directional diffusion of hafnium and carbon sources inside the HfC coating. The reaction of HfC coated carbon fibers with zirconium powders leads to the growth of ZrC on the HfC coating and this has been shown to occur by the diffusion of carbon from the carbon fiber core through the carbide coating to its surface