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Mullite fiber felt is a promising material that may fulfill the demands of advanced flexible external thermal insulation blankets. However, research on the fabrication and performance of mullite fiber felt with high-temperature resistance and thermal stability is still lacking. In this work, mullite fibers were selected as raw materials for the fabrication of mullite fibrous porous materials with a three-dimensional net structure. Said materials' high-temperature resistance and thermal stability were investigated by assessing the effects of various heat treatment temperatures (1100 °C, 1300 °C, and 1500 °C) on the phase composition, microstructure, and performance of their products. When the heat treatment temperature was below 1300 °C, both the phase compositions and microstructures of products exhibited stability. The compressive rebound rate of the product before and after 1100 °C reached 92.9% and 84.5%, respectively. The backside temperature of the as-prepared products was 361.6 °C when tested at 1500 °C for 4000 s. The as-prepared mullite fibrous porous materials demonstrated excellent high-temperature resistance, thermal stability, thermal insulation performance, and compressive rebound capacity, thereby indicating the great potential of the as-prepared mullite fibrous porous materials in the form of mullite fiber felt within advanced flexible external thermal insulation blankets. [ABSTRACT FROM AUTHOR]

Fibers crystallize and become brittle at high temperatures for a long time, so the surface coating must maintain long-lasting emission performance, which requires superior antioxidant properties of the high-emissivity fillers. To improve the radiation performance of the coating and the tensile strength of the fiber fabric, a double-layer coating with high emissivity was prepared on the surface of flexible aluminum silicate fiber fabric (ASFF) using MoSi2 and SiC as emissive agents. The incorporation of borosilicate glass into the outer coating during high-temperature oxidation of ZrB2 results in superior encapsulation of emitter particles, effectively filling the pores of the coating and significantly reducing the oxidation rate of MoSi2 and SiC. Furthermore, the addition of an intermediate ZrO2 layer enhances the fiber bundle's toughness. The obtained double-coated ASFF exhibits an exceptionally high tensile strength of 57.6 MPa and a high bond strength of 156.2 kPa. After being subjected to a 3 h heating process, the emissivity exhibits a minimal decrease of only 0.032, while still maintaining a high value above 0.9. The thermal insulation composites, consisting of a flexible ASFF matrix and a ZrB2-modified double-layer coating, exhibit significant potential for broad applications in the field of thermal protection. [ABSTRACT FROM AUTHOR]

Fibrous porous materials are one of the most commonly used high-temperature insulation materials because of their high porosity and low thermal conductivity. Due to their wide applications in the aerospace and energy industries, the investigation of high-elastic thermally insulating porous materials has attracted increasing attention. In order to improve the elasticity of fibrous porous materials, quartz fibers with high aspect ratio were used as matrix, sodium hexametaphosphate (SHMP) was selected as dispersant. We innovatively reported that a unique three-dimensional skeleton structure was constructed by adjusting the dispersion of fibers in the slurry, and the lightweight, thermal insulating and elastic SiO2 fibrous porous material was then prepared by the compression molding method. The characterization results of zeta potential and absorbance showed that the addition of SHMP was an effective method to enhance the dispersibility of quartz fibers in the slurry. SiO2 fibrous porous materials with 0.4 wt% SHMP content exhibited an ideal three-dimensional skeleton structure, which endowed the porous material with high porosity (89.39%), low density (0.04751 g/cm3), and low thermal conductivity (0.0356 W·m−1·K−1). The three-dimensional skeleton structure formed by overlapping fibers with high aspect ratios endowed the porous material with excellent elasticity. SiO2 fibrous porous materials with 0.4 wt% SHMP content could undergo large strains of 30% and achieved a resilience ratio of 81.69% under the 30th compression cycle. Moreover, after heat treatment at 800 °C, SiO2 fibrous porous materials also maintained good elasticity with a resilience ratio of more than 80%. [ABSTRACT FROM AUTHOR]