A method for forming a high temperature coating includes forming a pre-sintered ceramic coating on a ceramic composite substrate. The pre-sintered ceramic coating includes a plurality of ceramic particles. The method further includes sintering at least a portion of the pre-sintered ceramic coating by heating the portion of the pre-sintered ceramic coating to a sintering temperature of the plurality of ceramic particles using joule heating. The sintering temperature is greater than about 1000 degrees Celsius (° C.).

A method for forming a high temperature coating includes forming a pre-sintered ceramic coating on a ceramic composite substrate. The pre-sintered ceramic coating comprises a plurality of ceramic particles. The method further includes sintering at least a portion of the pre-sintered ceramic coating by heating the portion of the pre-sintered ceramic coating to a sintering temperature of the pre-sintered ceramic coating using one or more non-contact radiative heating elements. The sintering temperature is greater than about 1000 degrees Celsius (° C.).

A method for forming a high temperature coating includes forming a pre-sintered ceramic coating on a ceramic composite substrate. The pre-sintered ceramic coating comprises a plurality of ceramic particles. The method further includes sintering at least a portion of the pre-sintered ceramic coating by heating the portion of the pre-sintered ceramic coating to a sintering temperature of the pre-sintered ceramic coating using one or more non-contact radiative heating elements. The sintering temperature is greater than about 1000 degrees Celsius (° C.).

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and a network of gettering particles in the matrix phase. The gettering particles have an average maximum dimension between about 30 and 70 microns. The gettering particles have maximum dimensions that range from about 1 to 100 microns, and a dispersion of barium-magnesium alumino-silicate particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and a network of gettering particles in the matrix phase. The gettering particles have an average maximum dimension between about 30 and 70 microns. The gettering particles have maximum dimensions that range from about 1 to 100 microns, and a dispersion of barium-magnesium alumino-silicate particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and gettering particles in the matrix phase. The gettering particles with an aspect ratio greater than one are aligned such that a maximum dimension of the gettering particles extends along an axis that is generally parallel to the substrate. The barrier layer includes a dispersion of diffusive particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and gettering particles in the matrix phase. The gettering particles with an aspect ratio greater than one are aligned such that a maximum dimension of the gettering particles extends along an axis that is generally parallel to the substrate. The barrier layer includes a dispersion of diffusive particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

Systems and methods for forming an oxidation protection system on a composite structure are provided. In various embodiments, an oxidation protection system disposed on a substrate may comprise a boron-silicon-glass layer formed directly on the composite structure. The boron-silicon-glass layer may comprise a boron compound, a silicon compound, and a glass compound.

Systems and methods for forming an oxidation protection system on a composite structure are provided. In various embodiments, an oxidation protection system disposed on a substrate may comprise a boron-silicon-glass layer formed directly on the composite structure. The boron-silicon-glass layer may comprise a boron compound, a silicon compound, and a glass compound.

A barrier coating resin formulation comprising at least one polycarbosilane preceramic polymer, at least one organically modified silicon dioxide preceramic polymer, at least one filler, and at least one solvent. A barrier coating comprising a reaction product of the at least one polycarbosilane preceramic polymer and the at least one organically modified silicon dioxide preceramic polymer and the at least one filler is also disclosed, as are articles comprising the barrier coating, rocket motors comprising the barrier coating, and methods of forming the articles.