Advances in High-Performance Ceramic Materials for Aerospace and Defence Applications: A State-of-the-Art Review

Ceramic materials are indispensable to aerospace and defence technologies, where structural and functional components are required to withstand extreme thermal, mechanical, and chemically aggressive environments. Traditionally valued for their exceptional thermal stability, oxidation resistance, and corrosion resistance, ceramics have nonetheless been constrained by their inherent brittleness, which has limited their widespread adoption in load-bearing structural applications. This review surveys the principal tough ceramic systems currently employed in aerospace and defence, including SiC, Al2O3, ZrO2, Si3N4, SiC/SiC composites, and ultra-high-temperature ceramics (UHTCs) such as ZrB2 and HfB2. In parallel, it outlines advanced processing and manufacturing routes that enable enhanced microstructural control, improved reliability, and scalability for industrial deployment. Special attention is devoted to thermal and environmental barrier coatings (TBCs and EBCs), which provide critical protection against oxidation, corrosion, and severe thermal cycling in propulsion, power-generation, and hypersonic systems. Finally, the review highlights key material selection criteria for aerospace and defence platforms and discusses emerging trends that integrate tough ceramics with next-generation manufacturing technologies, underscoring their pivotal role in enabling high-performance, durable, and resilient systems for future extreme-environment applications.