Lightweight and thermally insulating aluminum borate nanofibrous porous ceramics

Aluminum borate porous ceramics are excellent candidates for high-temperature insulation applications. Current research on aluminum borate-based porous ceramics mainly focuses on porous ceramics made up of aluminum borate whiskers, whose low aspect ratio leads to a relatively dense porous structure; this results in porous ceramics with low porosity and relatively high thermal conductivity. In this study, we report the manufacturing of aluminum borate nanofibrous porous ceramics by an agar-based gel casting method using electrospun nanofibers with a high aspect ratio as the three-dimensional skeleton structure. We explored the effect of the alumina/boron oxide molar ratio on the microscopic morphology and crystal phase composition of the aluminum borate nanofibers and that of the sintering temperature on the micro and macro properties of porous ceramics based on the nanofibers. The results showed that aluminum borate nanofibers with an alumina/boron oxide molar ratio of 7:2 had the densest microscopic morphology, and the corresponding porous ceramics exhibited a higher porosity (91%) and lower thermal conductivity (0.11 W m−1 K−1) after sintering at 1200 °C than aluminum borate porous ceramics with aluminum borate whiskers as the skeleton. The successful synthesis of aluminum borate nanofibrous porous ceramics provides new insights into the development of high-temperature insulators.