CaZr4(PO4)6 (CZP) ceramics, owing to their unique low thermal expansion and low thermal conductivity, have shown great promise for high-temperature applications such as aerospace. However, their inherently low fracture toughness severely limits practical use. To simultaneously address the challenges of toughening while maintaining low thermal conductivity and low thermal expansion, this study employed slurry infiltration (SI) and fast hot-pressing (FHP) techniques at 1200 °C under 40 MPa for 10 min to fabricate three-dimensional needle-punched carbon fiber reinforced CZP composites (3D-Cf/CZP), using a carbon fiber preform with a bulk density of 0.27 g/cm3. Additionally, a pyrolytic carbon (PyC) interphase with a thickness of approximately 500 nm was introduced to produce 3D-Cf/PyC/CZP composites. The effects of carbon fibers and PyC coating on the microstructure, mechanical properties, and thermal behavior of CZP ceramics were systematically investigated. The results demonstrated excellent chemical compatibility and stable coexistence between the carbon fibers and the CZP matrix. The incorporation of three-dimensional carbon fibers significantly enhanced the fracture toughness of CZP ceramics, increasing from 1.46 ± 0.12 to 4.14 ± 0.35 MPa m1/2, and further to 6.83 ± 0.41 MPa m1/2 with the introduction of a PyC interfacial coating. This improvement is primarily attributed to multiple toughening mechanisms, including crack deflection, fiber pull-out, and interfacial debonding. The Cf/CZP composite retained a low coefficient of thermal expansion (CTE), exhibiting an average CTE of 0.95 × 10−6 °C−1, and the thermal conductivity (0.60–0.70 W m−1 K−1) was lower than that of the CZP matrix (0.85–0.95 W m−1 K−1). In contrast, the PyC coating increased the thermal conductivity of Cf/PyC/CZP composite (1.00–1.10 W m−1 K−1), but resulted in a further reduction in CTE to 0.71 × 10−6 °C−1, indicating a certain trade-off between interfacial toughening and thermal transport properties. This study confirms that the combination of 3D-Cf reinforcement and PyC coating can synergistically enhance the fracture toughness of CZP ceramics while maintaining their low thermal conductivity and low thermal expansion characteristics. However, the increase in thermal conductivity induced by the PyC layer, the stability issues of the material in oxidizing environments, and the still-required improvement in flexural strength are critical challenges that must be addressed synergistically in practical applications. These challenges collectively provide clear guidance for subsequent research directions, including interface optimization, oxidation protection, and mechanical performance enhancement.
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