Development of MAXCarbon: Advancing Hybrid Fibre Solutions for High-Performance Applications

The advancement of aerospace, energy, and hypersonic technologies has amplified the need for fibre materials that maintain structural integrity under extreme thermal and oxidative conditions. Conventional high-performance fibres such as carbon and silicon carbide (SiC), while exhibiting excellent mechanical properties, suffer from oxidative degradation above 1300 °C, thereby limiting their applicability in demanding environments. To address this limitation, RWTH Aachen has developed MAXCarbon, a novel hybrid fibre designed to enhance oxidation and corrosion resistance. MAXCarbon is produced by transforming commercially available continuous carbon fibres into hybrid fibres via a tailored reactive synthesis process, which generates a protective ceramic MAX-phase (Ti₃SiC₂) interface directly on the fibre surface. This process yields fibres with a carbon core and a Ti₃SiC₂ boundary layer, effectively combining the high tensile strength of carbon with the oxidation resistance of the MAX-phase. The resulting hybrid fibre offers promising potential for integration into advanced textile architectures and composite systems. Targeted applications include gas turbine components, thermal protection systems, high-temperature aerospace sensors, and electrochemical devices, where resistance to extreme thermal and oxidative environments is critical. The development of MAXCarbon not only represents a step forward in hybrid fibre technology but also contributes to strengthening European strategic autonomy in high-performance material production.