Low thermal conductivity and thermal radiation of La2Zr2O7 ceramics with hierarchical structure above 1000 K

The hierarchically porous La2Zr2O7 (LZO) microsphere fabricated by the electro-spraying assisted phase inversion (ESP) method is a promising feedstock for thermal barrier coatings (TBCs), due to its low thermal conductivity, quite high near-infrared reflectivity and high temperature structure stability. However, the thermal properties of hierarchically porous LZO ceramics above 1000 K are still unclear, limiting its application in TBCs. The effect of hierarchical structure on thermal conduction and thermal radiation was investigated in comparison with mono-sized pores, using the ESP microspheres (LZO-ESP) and other two carbon fillers to modulate the pores. The results showed that LZO-ESP samples exhibited ultra-low thermal conductivity (1.28 W m-1 K-1 at 1173 K), which was 30% lower than that of the reference samples of similar porosity. Heat flux simulation revealed that hierarchical structure can induce more disorder domains than the randomly distributed mono-sized pores. The disorder domains with high tortuosity of heat flux played a predominant role in the reduction of thermal conductivity. Additionally, the hierarchical structure significantly reduced thermal radiation by 36% compared with dense sample due to the decrease in transmissivity.