硅橡胶基绝热材料及其热化学烧蚀机理研究
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摘要
固体火箭冲压发动机补燃室是富燃料推进剂的富燃燃气与过量冲压空气掺混、燃烧和释放能量的主要场所。这种特殊的工作环境对补燃室绝热材料提出了抗氧化、耐烧蚀和抗冲刷等要求。柔性的硅橡胶基绝热材料具有优良的耐氧化特性，能够缓冲补燃室助推器药柱形变产生的应力，适合于补燃室富氧高温的烧蚀环境。目前，我国对硅橡胶基绝热材料配方和性能调节技术研究尚不成熟，对该类绝热材料的烧蚀结构和热化学烧蚀机理缺乏认识，这严重制约了该类绝热材料的快速研发。因此，认识硅橡胶基绝热材料配方与烧蚀率的内在联系、明确该类绝热材料的烧蚀结构及化学反应，进而揭示该类绝热材料的热化学烧蚀机理尤为重要。这些研究结果还可为该类绝热材料的配方设计、改进提供理论依据和指导，有利于进一步降低该类绝热材料在冲压发动机补燃室环境中的烧蚀率。
本文结合冲压发动机补燃室的烧蚀环境特点，以烧蚀过程中硅橡胶基绝热材料的烧蚀结构、组成和化学反应变化为核心，以该类绝热材料烧蚀过程中的热分解-陶瓷化-热氧化反应为纽带，系统研究了该类材料的热化学烧蚀特性。基于氧-乙炔焰和冲压发动机烧蚀实验，研究了硅橡胶基绝热材料配方组成和烧蚀环境对该类绝热材料烧蚀率的影响规律，明确了硅橡胶基绝热材料的烧蚀结构及组成，系统研究了烧蚀过程中该类绝热材料的热分解、陶瓷化和热氧化反应特征，获得了上述主要反应的热力学和动力学数据，明确了硅橡胶基绝热材料烧蚀结构、组成、反应与温度等环境参数的关系，揭示了硅橡胶基绝热材料的热化学烧蚀机理。建立了基于四层烧蚀结构（原始层、热解层、陶瓷层和烧蚀表层）的硅橡胶基绝热材料热化学烧蚀模型，数值研究了该类绝热材料烧蚀性能的影响因素。
在氧-乙炔焰烧蚀条件下，增大苯基硅橡胶和碳纤维含量、减小气相二氧化硅（SiO2）含量，有利于降低硅橡胶基绝热材料的烧蚀率。综合优化后的绝热材料配方为：50份甲基乙烯基硅橡胶、50份苯基硅橡胶、30份气相SiO2和15份碳纤维，其线烧蚀率为0.049mm·s-1。沿烧蚀方向，烧蚀后的硅橡胶基绝热材料依次形成了原始层、热解层、陶瓷层和烧蚀表层四层结构，陶瓷层厚度较大和组成致密的绝热材料具有较好的耐烧蚀性能。在陶瓷层中原位生成碳化硅（SiC），其含量约为8.1%；烧蚀表层的主要成份是SiO2。冲压发动机补燃室中烧蚀后硅橡胶基绝热材料发生膨胀，线烧蚀率为负值，陶瓷层孔隙率较大。与氧-乙炔焰烧蚀状态相比，冲压发动机补燃室燃烧温度较低、烧蚀时间较短，导致绝热材料陶瓷层中原位SiC含量偏低。在补燃室头部的高温、低氧环境烧蚀作用下，绝热材料烧蚀表面C含量较高，原始绝热材料剩余较少；在补燃室尾部的低温、高氧环境烧蚀作用下，绝热材料烧蚀表面SiO2含量较高，原始绝热材料剩余较多。
在氧-乙炔焰烧蚀条件下，典型硅橡胶基绝热材料的热解温度段约为765-943K。在该温度段，硅橡胶发生分解，碳纤维和二氧化硅保持稳定，最终形成多孔的热解层。因侧链苯基的位阻效应，苯基硅橡胶的热稳定性优于甲基乙烯基硅橡胶。硅橡胶受热主要发生环化分解，甲基乙烯基硅橡胶主要分解产物为甲基环硅氧烷，苯基硅橡胶液态产物中含有二苯基-多甲基环硅氧烷；硅橡胶热解过程中有部分侧链有机基团发生断裂和结构重排，产生小分子化合物；热分解过程中苯基硅橡胶的芳环结构发生高温缩合脱氢反应，并释放出氢气。甲基乙烯基硅橡胶和苯基硅橡胶热解固态产物的化学式分别为SiC0.90O1.11和SiC1.65O1.26。典型硅橡胶基绝热材料热解产物为碳纤维、SiO2、甲基乙烯基硅橡胶和苯基硅橡胶的固态热解产物。获得了典型硅橡胶基绝热材料及两种硅橡胶的热分解反应动力学方程。
在氧-乙炔焰烧蚀条件下，典型硅橡胶基绝热材料热解层的陶瓷化反应主要发生在943-2073K之间，包含芳构碳缩合脱氢、硅氧碳化物高温转化SiC陶瓷、C/SiO2反应生成SiC和SiO、SiO2熔化、SiC/SiO2反应等，最终形成由C、SiO2和SiC构成的陶瓷层。陶瓷层的多孔结构使其密度和导热系数比原始绝热材料下降一半以上，但943-1873K陶瓷化过程中材料的物性参数变化相对较小。1673K以上绝热材料陶瓷层中存在硅氧碳化物的高温转化反应和C/SiO2的碳热还原反应，这两种反应导致了SiC的原位生成。1873K时管式炉陶瓷层试样原位生成的SiC含量高达30.4%，并存在纳米SiC晶须。SiC具有还原性，高温下SiO2具有氧化性，陶瓷层中部分原位生成的SiC可与SiO2进一步发生反应生成SiO和CO。获得了典型硅橡胶基绝热材料热解层试样的陶瓷化反应及C/SiO2、SiC/SiO2反应的动力学方程。
硅橡胶基绝热材料陶瓷层的热氧化主要包括C、SiC分别与燃气中氧气（O2）、水（H2O）和二氧化碳（CO2）之间的反应，获得了这些反应及硅橡胶基绝热材料陶瓷层在O2、H2O和CO2混合氧化性气氛中的反应动力学方程。C的氧化反应在800-1400K之间快速进行，并导致了陶瓷层的失重；氧化性气体与C的反应速率大小关系是：O2>H2O>CO2。SiC优良耐氧化能力的发挥主要得益于产物SiO2对外部氧化性气体的隔离作用。原位生成的SiC不仅耐热氧化，还能将烧蚀形成的陶瓷层连接成牢固的整体结构，导致陶瓷层比C/SiO2/SiC混合物体系具有更好的耐热氧化性能。随着陶瓷层中C和SiC被逐渐氧化消耗，与高温氧化性环境接触的陶瓷层将会被氧化成以SiO2为主要成份的烧蚀表层。
建立了基于四层烧蚀结构（原始层、热解层、陶瓷层和烧蚀表层）的硅橡胶基绝热材料热化学烧蚀过程的物理模型和数学模型，用实验结果验证了模型的正确性；采用数值分析方法，研究了硅橡胶基绝热材料配方、烧蚀环境对硅橡胶基绝热材料耐烧蚀特性的影响规律。
In the secondary combustion chamber of the integral solid rocket ramjet, mix andcombustion are taken place between the hot fuel-rich gas from primary combustion of thefuel-rich propellant and the excessive ducted air stream. A lot of reaction heats are releasedduring the combustion process. Therefore, there are many requirements, such as, anti-oxidation,anti-ablation and anti-erosion, for the insulation material to be used in the secondary combustionchamber of solid ducted rocket. Silicone rubber based insulation material, a kind of elastomericmaterial with excellent anti-oxidative and mechanical properties, can meet these requirements.However, the technologies of the formulation design and performance adjustment about thesilicone rubber based insulation material has not been fully developed in our country, and theunderstanding about the ablation structure and thermochemical ablation mechanism of thematerials is quite lacked in China. Therefore, it is very important to disclose the correlationsbetween the insulation material formulation and the ablation rate, and to realize the ablationstructure and chemical reactions during the ablation process. The results in this dissertation arevery usefull in establishment of the ablation theory and decreaseing the ablation rate of thisinsulation material.
Based on the analysis of the ablative environment in the secondary combustion chamber ofthe integral solid rocket ramjet, the studies in this paper were focused on the ablation structures,the chemical reactions and their reaction products of the silicone rubber based insulation materialin the pyrolysis, ceramization and oxidation stages under the ablation process to realize theablative characteristics of the material systemically. Oxygen-acetylene ablation test and ramjetmotor test were employed to investigate the effects of ingredients and environmental parameterson the ablation rates of the insulation material. The reactions in the pyrolysis, ceramization andoxidation processes of the insulation material under the ablation test environments were studied.The thermodynamic and kinetic data of these reactions was obtained. The correlations betweenthe ablation structure, composition and reactions of the insulation material with environmentaltemperatures were deduced. Therefore, the thermochemical ablation mechanism of the siliconerubber based insulation material was established. An ablative model, which was based on theablation structure with virgin layer, pyrolysis layer, ceramic layer and surface layer, wasestablished. Finally, the effective factors on the ablation rates of the insulation material werenumerically studied.
The ablation rates of the insulation material from the oxygen-acetylene flame test werereduced by increasing the contents of phenyl silicone rubber and carbon fibers, or decreasing thecontent of silica. The optimum composition of silicone rubber based insulation material isconsist of50parts per hundred grams of rubber (phr) methylvinyl silicone rubber,50phr phenylsilicone rubber,30phr fumed silica and15phr carbon fibers, of which the ablation rate is0.049mm·s-1. After ablation, virgin layer, pyrolysis layer, ceramic layer and surface layer were observed along the ablation direction. The experimental results showed that the insulationmaterial with low ablation-rate generally formed a thick and firm ceramic layer. Siliconcarbide was in-situ produced in the ceramic layer. The content of silicon carbide in-situproduced in the ceramic layer of the optimum insulation material composition from theoxygen-acetylene ablation test is about8.1%. The surface layer is mainly consisted of silica.The insulation material samples expanded under the ablation environment of the ducted rocketsecondary combustion chamber. Therefore, the porosity of the ceramic layer is greater thanthat from oxygen-acetylene ablation test. Because of the low temperature and short ablationtime, the silicon carbide content of the ceramic layer formed in the secondary combustionchamber is lower than that produced under the oxygen-acetylene flame. In the front part of thesecondary combustion chamber, where the ablative environment is high temperature and lowoxidized gas level, a high carbon content was detected in the surface layer of the ablatedinsulation material sample, and a thin virgin layer was remained. In the back part of thesecondary combustion chamber, where the ablative environment is low temperature and highoxidized gas level, the ablated insulation material sample showed high silica content on thesurface and a thick virgin layer.
Under the oxygen-acetylene flame ablation condition, the temperature range of pyrolysisprocess for the typical silicone rubber based insulation material is765-943K. In thistemperature range, silicone rubbers decomposed, but carbon fibers and silica kept steady, so aporous pyrolysis layer of the insulation material is formed. The thermal stability of phenylsilicone rubber is better than that of the methylvinyl silicone rubber because of the blockingeffects of the phenyl groups. Circular type decomposition of silicone rubber took place.Dimethyl siloxane cycles are the main decomposition products of the silicone rubber with methyland vinyl groups, but diphenyl-multimethyl siloxane cycles are found in the liquiddecomposition products of the phenyl silicone rubber. Meanwhile, some other thermaldecomposition reactions, such as, side groups of silicone rubbers are ruptured from the polymerchain, and molecular redistribution reactions, take place to produce low molecular-weightcompounds. Polymerization of the aromatic groups from the themal decomposition of thesilicone rubber leads to produce hydrogen gas. The molecular formulas of the solid thermaldecompostion products pf the two silicone rubbers are SiC0.90O1.11and SiC1.65O1.26respectively.The pyrolysis layer sample of the typical silicone rubber based insulation material is consisted ofcarbon fibers, fumed silica and solid decomposition products of the two silicone rubbers. Thedecomposition kinetic equations of the typical silicone rubber based insulation material and thatof the two silicone rubbers were also obtained.
Under the oxygen-acetylene flame ablation condition, the temperature range of theceramization process from the pyrolysis layer is between943K and2073K. The reactions ofceramization process include the polymerization of aromatic structure, the transformation ofsiliconoxycarbide to carbide silicon, the reactions between carbon and silica, melting of silica,the reaction between silicon carbide and silica. The ceramic layer sample, which produced by the ceramization reaction from the pyrolysis layer, is mainly consisted of carbon, silica andsilicon carbide. The density and conductibility of the ceramic layer is less than half of these ofthe insulation material because of its porous structure. However, the changes of physical andstructure parameters of the ceramic layer are relatively low between943K and1873K. Whenthe temperature is more than1673K, the reactions of ceramization process to produced in-situsilicon carbide, such as, the siliconoxycarbide transformation, carbothermal reaction betweencarbon and silica, will take place. At1873K, the content of silicon carbide in the ceramic layermade from tube furnace is as high as30.4%, and nano silicon carbide whiskers are also observedin the sample. The reaction between reductive silicon carbide and oxidative silica could occurto produce silicon monoxide and carbon monoxide. The kinetic equation of the ceramizationreaction of the typical silicone rubber based insulation material pyrolysis layer was obtained, aswell as the kinetic equations of the carbon and silica reaction, silicon carbide and silica reaction.
During the oxidation process of ceramic layer sample, the reactions of C/O2, C/H2O, C/CO2.SiC/O2, SiC/H2O, and SiC/CO2will take place. The kinetic equations of these oxidationreactions of ceramic layer sample, carbon and silicon carbide with oxygen, water or carbondioxide were gained. Carbon could be quickly oxidized between800K and1400K, which leadsto the weight loss of ceramic layer. The oxidation rate of carbon became faster according to thesequence of carbon dioxide, water, oxygen. Silicon carbon showed good anti-oxidationproperties because silica was produced by the oxidation and obstructed silicon carbide fromoxidized gas. Besides its nice oxidation resistance, the in-situ produced silicon carbides have acapability of bonding the ingredients of the ceramic layer together to make a whole structure inthe ceramic layer. So the thermooxidative stability of the ceramic layer is better than that of themixture of carbon, silica and silicon carbide. When the carbon and silicon carbide in theceramic layer were oxidized by the oxidative gas under the high temperature environment, anablation surface layer mainly composited by silica was formed.
Physical and numerical ablation models of the silicone rubber based insulation material,which considered four layers ablation structure (virgin layer, pyrolysis layer, ceramic layer andablation surface layer), were established. The calculation results were validated by theexperiment data. The effects of ingredients and ablative environment on the ablative rates ofsilicone rubber based insulation material were numerically studied.
本文结合冲压发动机补燃室的烧蚀环境特点，以烧蚀过程中硅橡胶基绝热材料的烧蚀结构、组成和化学反应变化为核心，以该类绝热材料烧蚀过程中的热分解-陶瓷化-热氧化反应为纽带，系统研究了该类材料的热化学烧蚀特性。基于氧-乙炔焰和冲压发动机烧蚀实验，研究了硅橡胶基绝热材料配方组成和烧蚀环境对该类绝热材料烧蚀率的影响规律，明确了硅橡胶基绝热材料的烧蚀结构及组成，系统研究了烧蚀过程中该类绝热材料的热分解、陶瓷化和热氧化反应特征，获得了上述主要反应的热力学和动力学数据，明确了硅橡胶基绝热材料烧蚀结构、组成、反应与温度等环境参数的关系，揭示了硅橡胶基绝热材料的热化学烧蚀机理。建立了基于四层烧蚀结构（原始层、热解层、陶瓷层和烧蚀表层）的硅橡胶基绝热材料热化学烧蚀模型，数值研究了该类绝热材料烧蚀性能的影响因素。
在氧-乙炔焰烧蚀条件下，增大苯基硅橡胶和碳纤维含量、减小气相二氧化硅（SiO2）含量，有利于降低硅橡胶基绝热材料的烧蚀率。综合优化后的绝热材料配方为：50份甲基乙烯基硅橡胶、50份苯基硅橡胶、30份气相SiO2和15份碳纤维，其线烧蚀率为0.049mm·s-1。沿烧蚀方向，烧蚀后的硅橡胶基绝热材料依次形成了原始层、热解层、陶瓷层和烧蚀表层四层结构，陶瓷层厚度较大和组成致密的绝热材料具有较好的耐烧蚀性能。在陶瓷层中原位生成碳化硅（SiC），其含量约为8.1%；烧蚀表层的主要成份是SiO2。冲压发动机补燃室中烧蚀后硅橡胶基绝热材料发生膨胀，线烧蚀率为负值，陶瓷层孔隙率较大。与氧-乙炔焰烧蚀状态相比，冲压发动机补燃室燃烧温度较低、烧蚀时间较短，导致绝热材料陶瓷层中原位SiC含量偏低。在补燃室头部的高温、低氧环境烧蚀作用下，绝热材料烧蚀表面C含量较高，原始绝热材料剩余较少；在补燃室尾部的低温、高氧环境烧蚀作用下，绝热材料烧蚀表面SiO2含量较高，原始绝热材料剩余较多。
在氧-乙炔焰烧蚀条件下，典型硅橡胶基绝热材料的热解温度段约为765-943K。在该温度段，硅橡胶发生分解，碳纤维和二氧化硅保持稳定，最终形成多孔的热解层。因侧链苯基的位阻效应，苯基硅橡胶的热稳定性优于甲基乙烯基硅橡胶。硅橡胶受热主要发生环化分解，甲基乙烯基硅橡胶主要分解产物为甲基环硅氧烷，苯基硅橡胶液态产物中含有二苯基-多甲基环硅氧烷；硅橡胶热解过程中有部分侧链有机基团发生断裂和结构重排，产生小分子化合物；热分解过程中苯基硅橡胶的芳环结构发生高温缩合脱氢反应，并释放出氢气。甲基乙烯基硅橡胶和苯基硅橡胶热解固态产物的化学式分别为SiC0.90O1.11和SiC1.65O1.26。典型硅橡胶基绝热材料热解产物为碳纤维、SiO2、甲基乙烯基硅橡胶和苯基硅橡胶的固态热解产物。获得了典型硅橡胶基绝热材料及两种硅橡胶的热分解反应动力学方程。
在氧-乙炔焰烧蚀条件下，典型硅橡胶基绝热材料热解层的陶瓷化反应主要发生在943-2073K之间，包含芳构碳缩合脱氢、硅氧碳化物高温转化SiC陶瓷、C/SiO2反应生成SiC和SiO、SiO2熔化、SiC/SiO2反应等，最终形成由C、SiO2和SiC构成的陶瓷层。陶瓷层的多孔结构使其密度和导热系数比原始绝热材料下降一半以上，但943-1873K陶瓷化过程中材料的物性参数变化相对较小。1673K以上绝热材料陶瓷层中存在硅氧碳化物的高温转化反应和C/SiO2的碳热还原反应，这两种反应导致了SiC的原位生成。1873K时管式炉陶瓷层试样原位生成的SiC含量高达30.4%，并存在纳米SiC晶须。SiC具有还原性，高温下SiO2具有氧化性，陶瓷层中部分原位生成的SiC可与SiO2进一步发生反应生成SiO和CO。获得了典型硅橡胶基绝热材料热解层试样的陶瓷化反应及C/SiO2、SiC/SiO2反应的动力学方程。
硅橡胶基绝热材料陶瓷层的热氧化主要包括C、SiC分别与燃气中氧气（O2）、水（H2O）和二氧化碳（CO2）之间的反应，获得了这些反应及硅橡胶基绝热材料陶瓷层在O2、H2O和CO2混合氧化性气氛中的反应动力学方程。C的氧化反应在800-1400K之间快速进行，并导致了陶瓷层的失重；氧化性气体与C的反应速率大小关系是：O2>H2O>CO2。SiC优良耐氧化能力的发挥主要得益于产物SiO2对外部氧化性气体的隔离作用。原位生成的SiC不仅耐热氧化，还能将烧蚀形成的陶瓷层连接成牢固的整体结构，导致陶瓷层比C/SiO2/SiC混合物体系具有更好的耐热氧化性能。随着陶瓷层中C和SiC被逐渐氧化消耗，与高温氧化性环境接触的陶瓷层将会被氧化成以SiO2为主要成份的烧蚀表层。
建立了基于四层烧蚀结构（原始层、热解层、陶瓷层和烧蚀表层）的硅橡胶基绝热材料热化学烧蚀过程的物理模型和数学模型，用实验结果验证了模型的正确性；采用数值分析方法，研究了硅橡胶基绝热材料配方、烧蚀环境对硅橡胶基绝热材料耐烧蚀特性的影响规律。
In the secondary combustion chamber of the integral solid rocket ramjet, mix andcombustion are taken place between the hot fuel-rich gas from primary combustion of thefuel-rich propellant and the excessive ducted air stream. A lot of reaction heats are releasedduring the combustion process. Therefore, there are many requirements, such as, anti-oxidation,anti-ablation and anti-erosion, for the insulation material to be used in the secondary combustionchamber of solid ducted rocket. Silicone rubber based insulation material, a kind of elastomericmaterial with excellent anti-oxidative and mechanical properties, can meet these requirements.However, the technologies of the formulation design and performance adjustment about thesilicone rubber based insulation material has not been fully developed in our country, and theunderstanding about the ablation structure and thermochemical ablation mechanism of thematerials is quite lacked in China. Therefore, it is very important to disclose the correlationsbetween the insulation material formulation and the ablation rate, and to realize the ablationstructure and chemical reactions during the ablation process. The results in this dissertation arevery usefull in establishment of the ablation theory and decreaseing the ablation rate of thisinsulation material.
Based on the analysis of the ablative environment in the secondary combustion chamber ofthe integral solid rocket ramjet, the studies in this paper were focused on the ablation structures,the chemical reactions and their reaction products of the silicone rubber based insulation materialin the pyrolysis, ceramization and oxidation stages under the ablation process to realize theablative characteristics of the material systemically. Oxygen-acetylene ablation test and ramjetmotor test were employed to investigate the effects of ingredients and environmental parameterson the ablation rates of the insulation material. The reactions in the pyrolysis, ceramization andoxidation processes of the insulation material under the ablation test environments were studied.The thermodynamic and kinetic data of these reactions was obtained. The correlations betweenthe ablation structure, composition and reactions of the insulation material with environmentaltemperatures were deduced. Therefore, the thermochemical ablation mechanism of the siliconerubber based insulation material was established. An ablative model, which was based on theablation structure with virgin layer, pyrolysis layer, ceramic layer and surface layer, wasestablished. Finally, the effective factors on the ablation rates of the insulation material werenumerically studied.
The ablation rates of the insulation material from the oxygen-acetylene flame test werereduced by increasing the contents of phenyl silicone rubber and carbon fibers, or decreasing thecontent of silica. The optimum composition of silicone rubber based insulation material isconsist of50parts per hundred grams of rubber (phr) methylvinyl silicone rubber,50phr phenylsilicone rubber,30phr fumed silica and15phr carbon fibers, of which the ablation rate is0.049mm·s-1. After ablation, virgin layer, pyrolysis layer, ceramic layer and surface layer were observed along the ablation direction. The experimental results showed that the insulationmaterial with low ablation-rate generally formed a thick and firm ceramic layer. Siliconcarbide was in-situ produced in the ceramic layer. The content of silicon carbide in-situproduced in the ceramic layer of the optimum insulation material composition from theoxygen-acetylene ablation test is about8.1%. The surface layer is mainly consisted of silica.The insulation material samples expanded under the ablation environment of the ducted rocketsecondary combustion chamber. Therefore, the porosity of the ceramic layer is greater thanthat from oxygen-acetylene ablation test. Because of the low temperature and short ablationtime, the silicon carbide content of the ceramic layer formed in the secondary combustionchamber is lower than that produced under the oxygen-acetylene flame. In the front part of thesecondary combustion chamber, where the ablative environment is high temperature and lowoxidized gas level, a high carbon content was detected in the surface layer of the ablatedinsulation material sample, and a thin virgin layer was remained. In the back part of thesecondary combustion chamber, where the ablative environment is low temperature and highoxidized gas level, the ablated insulation material sample showed high silica content on thesurface and a thick virgin layer.
Under the oxygen-acetylene flame ablation condition, the temperature range of pyrolysisprocess for the typical silicone rubber based insulation material is765-943K. In thistemperature range, silicone rubbers decomposed, but carbon fibers and silica kept steady, so aporous pyrolysis layer of the insulation material is formed. The thermal stability of phenylsilicone rubber is better than that of the methylvinyl silicone rubber because of the blockingeffects of the phenyl groups. Circular type decomposition of silicone rubber took place.Dimethyl siloxane cycles are the main decomposition products of the silicone rubber with methyland vinyl groups, but diphenyl-multimethyl siloxane cycles are found in the liquiddecomposition products of the phenyl silicone rubber. Meanwhile, some other thermaldecomposition reactions, such as, side groups of silicone rubbers are ruptured from the polymerchain, and molecular redistribution reactions, take place to produce low molecular-weightcompounds. Polymerization of the aromatic groups from the themal decomposition of thesilicone rubber leads to produce hydrogen gas. The molecular formulas of the solid thermaldecompostion products pf the two silicone rubbers are SiC0.90O1.11and SiC1.65O1.26respectively.The pyrolysis layer sample of the typical silicone rubber based insulation material is consisted ofcarbon fibers, fumed silica and solid decomposition products of the two silicone rubbers. Thedecomposition kinetic equations of the typical silicone rubber based insulation material and thatof the two silicone rubbers were also obtained.
Under the oxygen-acetylene flame ablation condition, the temperature range of theceramization process from the pyrolysis layer is between943K and2073K. The reactions ofceramization process include the polymerization of aromatic structure, the transformation ofsiliconoxycarbide to carbide silicon, the reactions between carbon and silica, melting of silica,the reaction between silicon carbide and silica. The ceramic layer sample, which produced by the ceramization reaction from the pyrolysis layer, is mainly consisted of carbon, silica andsilicon carbide. The density and conductibility of the ceramic layer is less than half of these ofthe insulation material because of its porous structure. However, the changes of physical andstructure parameters of the ceramic layer are relatively low between943K and1873K. Whenthe temperature is more than1673K, the reactions of ceramization process to produced in-situsilicon carbide, such as, the siliconoxycarbide transformation, carbothermal reaction betweencarbon and silica, will take place. At1873K, the content of silicon carbide in the ceramic layermade from tube furnace is as high as30.4%, and nano silicon carbide whiskers are also observedin the sample. The reaction between reductive silicon carbide and oxidative silica could occurto produce silicon monoxide and carbon monoxide. The kinetic equation of the ceramizationreaction of the typical silicone rubber based insulation material pyrolysis layer was obtained, aswell as the kinetic equations of the carbon and silica reaction, silicon carbide and silica reaction.
During the oxidation process of ceramic layer sample, the reactions of C/O2, C/H2O, C/CO2.SiC/O2, SiC/H2O, and SiC/CO2will take place. The kinetic equations of these oxidationreactions of ceramic layer sample, carbon and silicon carbide with oxygen, water or carbondioxide were gained. Carbon could be quickly oxidized between800K and1400K, which leadsto the weight loss of ceramic layer. The oxidation rate of carbon became faster according to thesequence of carbon dioxide, water, oxygen. Silicon carbon showed good anti-oxidationproperties because silica was produced by the oxidation and obstructed silicon carbide fromoxidized gas. Besides its nice oxidation resistance, the in-situ produced silicon carbides have acapability of bonding the ingredients of the ceramic layer together to make a whole structure inthe ceramic layer. So the thermooxidative stability of the ceramic layer is better than that of themixture of carbon, silica and silicon carbide. When the carbon and silicon carbide in theceramic layer were oxidized by the oxidative gas under the high temperature environment, anablation surface layer mainly composited by silica was formed.
Physical and numerical ablation models of the silicone rubber based insulation material,which considered four layers ablation structure (virgin layer, pyrolysis layer, ceramic layer andablation surface layer), were established. The calculation results were validated by theexperiment data. The effects of ingredients and ablative environment on the ablative rates ofsilicone rubber based insulation material were numerically studied.
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