To enhance the high-temperature oxidation resistance of carbon-based materials through optimized ceramic coating structures, a borosilicate glass (BSG)-modified ZrB2-MoSi2-BSG gradient composite coating was successfully fabricated via in-situ self-assembly induced by thermal expansion mismatch. The influence of densification temperature on the oxygen-blocking microstructure and oxidation resistance of the composite coating was systematically investigated. Results indicate that when the densification temperature exceeds 1300 ℃, a gradient oxygen-blocking structure is formed via self-assembly during high-temperature oxidation protection. With increasing densification temperature, the interfacial bonding strength between the coating and the substrate initially increases and then decreases, reaching an optimum performance at a specific temperature. The maximum bonding strength achieved was 84.6 N, accompanied by a minimal oxidation weight gain of 0.24 × 10−2 g·cm−2 after 100 min at 1700 ℃. Additionally, the oxygen transmission rate was as low as 0.04 %, the carbon loss rate was 0.13 × 10−6 g·cm−2·s−1, and the cumulative protection efficiency reached 99.95 %. However, further increasing the sintering temperature leads to excessive accumulation of self-assembled SiO2 layers at the coating interface, resulting in structural defects such as pores and cracks within the coating. These defects provide pathways for oxygen permeation, thereby degrading the oxidation resistance of the coating. This study demonstrates that thermal expansion mismatch can be effectively utilized to induce gradient in-situ self-assembly in BSG-modified ZrB2-MoSi2 composite coatings, enabling effective regulation of glass phase distribution and interfacial structure through optimized sintering temperatures. This approach provides a viable strategy for the controllable structural design and highly efficient oxygen-blocking protection of ultra-high temperature ceramic coatings.
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