Lightweight, strong, and thermally insulating polybenzoxazine aerogel thermal protection composites for antioxidant ablation long to 1800 s

The lightweight ablation materials that have been successfully applied in thermal protection systems (TPS) are the focus of attention owing to the urgent demand for aerospace vehicles to have efficient thermal insulation materials with lightweight, long-term antioxidant, and micro-ablation. However, improving the antioxidant ablation properties in a long-term aerobic atmosphere is still a significant challenge. Herein, a novel strategy to fabricate needle quartz fiber (NQF) reinforced SiO2 aerogel interpenetrating polybenzoxazine (PBO) aerogel thermal protection composites (NQF/SiO2–PBOs) with a binary network structure is proposed. The as-prepared NQF/SiO2–PBOs perfectly inherited their porous nanostructure and captivating properties, including lightweight (0.53 g/cm3), high mechanical strengths, and low thermal conductivity of 0.048 W/(m·K) at 25 °C and 0.079 W/(m·K) at 1100 °C. Moreover, the NQF/SiO2–PBOs exhibited outstanding high-temperature thermal insulation and long-time antioxidant ablation with low linear and mass ablation rates. The cold surface temperature peaked at approximately 307.2 °C within 1800 s when the hot surface temperature exceeded 1100 °C. The ablation/thermal insulation mechanism was also discussed through the analysis of the microstructure, chemical structure, and crystal structure. This research provides a meaningful reference for the development and exploitation of new advanced lightweight, long-term antioxidant, and micro-ablative thermal protective materials.