Biomimetic structure-driven high strength and toughness in continuous SiC skeleton-reinforced graphite composites

Graphite-matrix structural composites with excellent mechanical properties and long-term reliability are ungently required in aerospace and nuclear industries. However, the enhancement of graphite-matrix composites by mainstream surface coating techniques or second-phase particle reinforcement is rather limited. Inspired by the structural-functional feature of plant cells, silicon carbide (SiC, cytoderm) coated mesocarbon microbeads (MCMB, cytoplasm) powders were prepared by combustion synthesis (CS), which were then densified via spark plasma sintering (SPS) to obtain the biomimetic cellular-structured SiC-reinforced MCMB (M@SiC) composites. The in-situ formed SiC ‘cytoderm’ ensures good interfacial bonding and contributed to the densification of the composites. Additionally, the continuous SiC skeleton and cellular-structured configuration improved the mechanical properties of M@SiC composites. Owing to the complex crack deflection, branching and bridging effects at the MCMB/SiC interfaces and graphite nanoflakes inside MCMB, the biomimetic M@SiC composite with SiC content of 47 vol% exhibited strengthening and toughening, with flexural strength and fracture toughness of 245 MPa and 3.82 MPa m^1/2, respectively. The developed biomimetic graphite-matrix composites with excellent mechanical properties are expected to be applied in reusable spacecrafts and high-temperature gas-cooled reactors.