Processing and Testing of Ultrahigh Temperature Structural Ceramic Foams

Ultramet has developed innovative processing for ultrahigh temperature structural ceramic foams that can be produced in various pore sizes from various ceramic materials. Highly insulating and lightweight thermal protection materials have been produced by combining an open-cell carbon or ceramic foam skeleton with an ultralow density aerogel filler material. The foam serves as an easily machinable structural reinforcement for the very low-strength aerogel insulator and defines the shape of the component. In the foam-aerogel composite structure, the aerogel exists in small discrete cells and is supported by the foam skeleton. The combined density of the composite insulator is as low as 0.1 g/cm³, and the thermal conductivity is <1 W/m·K at 2000°C. Single-piece panels up to 30" square are feasible. In addition to thermal insulation, ceramic foams have been used as catalyst supports and for turbine engine noise reduction. Processing and testing of ceramic foam materials will be discussed.