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J. Korean Ceram. Soc. > Volume 61(1); 2024 > Article
Journal of the Korean Ceramic Society 2024;61(1): 142-152.
doi: https://doi.org/10.1007/s43207-023-00337-x
Low thermal conductivity and high durability porous thermal insulation coating via room–temperature spray coating process
Sae-Jung Yun1,2, Jung-Hwan Kim1, Hyun-Ae Cha1, Cheol-Woo Ahn1, Young Kook Moon1, Jongmoon Jang1, Woon-Ha Yoon1, Jong-Jin Choi1, Byung-Dong Hahn1,2
1Department of Functional Ceramics, Ceramic Materials Division, Korea Institute of Materials Science (KIMS), Changwon, Gyeongnam, 51508, Korea
2Department of Advanced Materials Engineering, Korea University of Science and Technology, Daejeon, 34113, Korea
Correspondence  Jong-Jin Choi ,Email: finaljin@kims.re.kr
Byung-Dong Hahn ,Email: cera72@kims.re.kr
Received: May 15, 2023; Revised: September 24, 2023   Accepted: October 8, 2023.  Published online: November 2, 2023.
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.
Key words: Aerosol deposition · Thermal insulation · Porous coating · Adhesion strength · Y2O3 thick film · Thermal conductivity · ZrSiO4 thick film
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