Facile synthesis of dense SiBCN coatings with excellent compactness, smoothness, and high-temperature inertness on defective graphite surfaces

SiBCN ceramics possess extreme high-temperature stability among engineering ceramics; however, their application is constrained by the difficulty in achieving large continuous products at low cost. This work exhibits the possibility of fabricating SiBCN continuous coatings on graphite substrates to improve their surface integrity, hardness, and inertness. The ceramic coatings were fabricated simply by spin coating, curing, and pyrolysis. The key innovations are the synthesis of the precursor, polyborosilazane (PBSZ), that derives continuous ceramic films after pyrolysis, and the finding that the xylene solution of PBSZ can achieve a very good spinning performance on various surfaces, especially the low-quality graphite surfaces with holes. The fabricated SiBCN coatings, characterized to be networks of Si–C, Si–N, C–C, and B–N bonds, possessed smooth and hard surfaces with roughness below 9 nm and a hardness of 7.3 GPa. The coating thickness can be well controlled in the range of 1.4 – 2.1 μm as the latter is linearly dependent on the concentration of PBSZ in the solution. Detailed observations of surface morphologies and physisorption experiments reveal that the coating surfaces are crack-free and highly dense, rendering a significant reduction in specific surface areas when a defective graphite face is coated.