High porosity and low thermal conductivity lanthanum zirconate porous ceramics via replica method

Low thermal conductivity and excellent high-temperature stability make lanthanum zirconate (La₂Zr₂O₇, LZO) a very promising material for high-temperature insulation applications. In this study, LZO porous ceramics with ultra-high porosity and an open-pore structure were prepared by the replica method using a polyurethane template. The flowability and coating quality of the ceramic slurry were optimized. When the dispersant content of the slurry was 0.6 wt% and the alcohol to water ratio was 1:1, the slurry had low surface tension and low viscosity, leading to good coating quality of the ceramic slurry on the sponge template. The pore size between hollow skeletons was 100–500 μm with the hollow structure of the skeletons forming secondary pores. LZO porous ceramics showed high porosity of 87.6%-96.0%, low thermal conductivity of 0.048–0.126 W/(m·K), and compressive strength of 0.13–0.74 MPa by adjusting the ceramic content. A high temperature insulation performance test showed that the temperature difference between the cold side and the hot side of the sample was over 1000°C, indicating the excellent thermal insulation properties of LZO porous ceramics. LZO porous ceramics had good high-temperature stability without sintering shrinkage at heat treatment temperatures below 1500°C.