Insulating and Robust Ceramic Nanorod Aerogels with High-Temperature Resistance over 1400 °C

Ceramic aerogels, which present a unique combination of low thermal conductivity and excellent high-temperature stability, are attractive for thermal insulation under extreme conditions. However, most ceramic aerogels are constructed by oxide ceramic nanoparticles and thus are usually plagued by their brittleness and structural collapse at elevated temperatures (less than 1000 °C). Despite great progress achieved in this regard recently, it still remains a big challenge to design and fabricate intriguing ceramic aerogels with enhanced mechanical strength and remarkable thermal stability at ultrahigh temperature up to 1400 °C. To this end, we herein report a facile and scalable strategy to manufacture ceramic nanorod aerogels (CNRAs) with hierarchically macroporous and mesoporous structures by the controllable assembly of Al₂O₃ nanorods and SiO₂ nanoparticles. Subsequently, the high-temperature annealing treatment of CNRAs significantly maximizes mechanical strength and promotes thermal tolerance. The obtained CNRAs demonstrate the integrated properties of super-strong heat resistance (up to 1400 °C), low thermal conductivity (0.026 W/m·K at 25 °C and 0.089 W/m·K at 1200 °C), high mechanical robustness (compressive strength 1.5 MPa), and low density (0.146 g/cm³). We envision that this novel nanorod-assembled ceramic aerogels offer considerable advantages than most of the state-of-the-art ceramic aerogels for thermal superinsulation upon exposure to extremely harsh environments.