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Low thermal conductivity and high durability porous thermal insulation coating via room–temperature spray coating process

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Abstract

Herein, an efficient approach using aerosol deposition (AD) is proposed to fabricate a porous ceramic film with high thermal insulating and adhesive properties. Polyethylene powder (PE) is incorporated to regulate the kinetic energy of the ZrSiO4 powder, which hinders the formation of structurally stable film layers. During the high-energy milling process, the ZrSiO4-PE composite powder agglomerates suitably and exhibits adequate kinetic energy to produce a porous film. Despite its exceptional thermally insulating characteristics, the ZrSiO4-PE composite film demonstrates relatively poor adhesion properties. Consequently, an optimized quantity of Y2O3 powder is blended to modulate the thermal insulating and mechanical adhesion properties of the porous coating films. The Y2O3-(ZrSiO4-PE) composite film (approximately 60 μm) exhibits low density (2.2 g/cm3), low thermal conductivity (at ambient temperature, approximately 0.64 W/m∙K), and excellent adhesion strength (37 MPa) attributes. This research offers valuable guidance for fabricating composite porous ceramic films with low thermal conductivity and high adhesion at room temperatures using AD.

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The datasets used and/or analysed during the current study available from the corresponding author on reasonable request.

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Acknowledgements

This work was supported by the Technology Innovation Program (Development of 30 μm ceramic beads and reliability evaluation technology, No. 20011008) funded by the Ministry of Trade, Industry & Energy (MOTIE, Korea) and the Korea Institute of Materials Science (KIMS) internal R&D program (No. PNK8830).

Funding

Korea Evaluation Institute of Industrial Technology, 20011008, JongJin Choi, Korea Institute of Materials Science, PNK8830.

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Authors and Affiliations

  1. Department of Functional Ceramics, Ceramic Materials Division, Korea Institute of Materials Science (KIMS), Changwon, Gyeongnam, 51508, Korea

    Sae-Jung Yun, Jung-Hwan Kim, Hyun-Ae Cha, Cheol-Woo Ahn, Young Kook Moon, Jongmoon Jang, Woon-Ha Yoon, Jong-Jin Choi & Byung-Dong Hahn

  2. Department of Advanced Materials Engineering, Korea University of Science and Technology, Daejeon, 34113, Korea

    Sae-Jung Yun & Byung-Dong Hahn

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  1. Sae-Jung Yun
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Yun, SJ., Kim, JH., Cha, HA. et al. Low thermal conductivity and high durability porous thermal insulation coating via room–temperature spray coating process. J. Korean Ceram. Soc. 61, 142–152 (2024). https://doi.org/10.1007/s43207-023-00337-x

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