Lightweight porous mullite-silica ceramics with multistage pore structure, low thermal conductivity and improved strength

Thermal protection was always a prominent issue in the aerospace industry. For vehicle safety, reliability and payload requirements, thermal protection materials were usually expected to possess low density, superior mechanical and thermal insulation properties. Here, lightweight and high-strength porous mullite-silica ceramics were manufactured using particle-stabilized foaming technique. The strength and thermal insulation properties of porous ceramics modified with hollow silica spheres were significantly enhanced. A 10 wt% hollow spheres addition achieved a 28.9 % increase in strength and a 33.4 % decrease in thermal conductivity with almost constant porosity (from 86.39 % to 87.04 %). Considering the characteristics of light weight, high compression strength and superior thermal insulation performance, porous ceramics could be applied as thermal protection materials in the aerospace sector.