High-aspect-ratio ZrC whiskers: Synthesis, growth mechanism and electromagnetic wave absorption properties

Stealth materials with high dependability at elevated temperatures and outstanding mechanical properties are urgently needed for practical applications. As one-dimensional ultrahigh temperature ceramic (UHTC) materials, zirconium carbide whiskers (ZrCw) have attracted a great deal of attention due to their desirable mechanical and ablation resistance performance in high-temperature environments. We have successfully synthesized ZrCw using a carbothermal reduction technique without the introduction of metal catalytic in this paper. ZrCw shows a typically prismatic structure with the diameter of 1–2 μm and the aspect ratio of up to 250. The growth of ZrCw is controlled by a solid-liquid-solid (SLS) and vapor-solid (VS) compound mechanism in conjunction with the auxiliary action of mesophase Na₃ZrF₇. The ZrCw/paraffin hybrids achieve the minimum reflection loss (R_L(min)) of −25.77 dB at 13.28 GHz under the thickness of 1.25 mm, and reach an effective absorption bandwidth (EAB) of 3.04 GHz (14.96–18.00 GHz) with a thickness of only 1.0 mm. This work presents a promising approach for large-scale producing high-purity whiskers, and verifies that ZrCw has extensive application prospects in the field of stealth materials.