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Preparing Silica Aerogel Monoliths via a Rapid Supercritical Extraction Method

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Superstrong Lightweight Aerogel with Supercontinuous Layer by Surface Reaction.

Tianpei Zhou¹, Linbo He¹, Yu Zhen¹

¹Key Laboratory of Precision and Intelligent Chemistry, CAS Key Laboratory of Mechanical Behavior and Design of Materials, Department of Precision Machinery and Precision Instrumentation, National Synchrotron Radiation Laboratory, Center for Micro and Nanoscale Research and Fabrication, Institute of Advanced Technology, University of Science and Technology of China, Hefei, 230026, P. R. China.

Advanced Materials (Deerfield Beach, Fla.)

|January 28, 2025

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Researchers developed a new method to create a supercontinuous zirconium dioxide (ZrO2) nanolayer on aerogel fibers. This significantly enhances aerogel strength, impact resistance, and temperature stability without increasing density.

Area of Science:

Materials Science
Nanotechnology
Ceramic Engineering

Background:

Aerogels possess excellent thermal and lightweight properties but are limited by discrete grain and nano-unit interfaces.
Existing aerogels struggle to meet demands for advanced thermal protection, energy utilization, and high-temperature applications due to performance limitations.

Purpose of the Study:

To overcome the performance limitations of aerogels by enhancing their thermal and mechanical properties.
To develop a novel method for creating a continuous nanolayer on aerogel surfaces for improved structural integrity.

Main Methods:

A thermodynamically driven surface reaction and confined crystallization process was employed.
A centimeter-scale supercontinuous zirconium dioxide (ZrO2) nanolayer was synthesized on ZrO2-SiO2 fiber aerogel surfaces.

Keywords:

aerogel supercontinuous layer superstrong and ultralight surface chemistry reaction thermal insulation

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Main Results:

The synthesized aerogel exhibited a density of approximately 26 mg cm⁻³, with significantly improved thermal and mechanical performance.
Record-breaking specific strength (≈84615 N m kg⁻¹) and dynamic impact resistance (withstanding impacts up to 500 times aerogel mass) were achieved.
Enhanced temperature resistance was demonstrated, with stability at 1500 °C and a 400 °C enhancement.

Conclusions:

The supercontinuous ZrO2 nanolayer, formed via Zr─O─Si bonds, effectively connects grains and fibers, enhancing aerogel properties.
This approach provides a new pathway for pushing the limits of lightweight, high-strength, and thermally stable solid materials.