Mullite photonic glasses with exceptional thermal stability for novel reflective thermal barrier coatings

Abstract

Thermal barrier coatings are essential materials systems for insulating and protecting substrates exposed to high temperatures. In such systems, the heat transfer has three possible paths: conduction, convection and irradiation. The higher the operating temperature, the more important it is to control or protect against the radiative component, since the radiative heat flux becomes non-negligible. The radiation can be controlled by the use of ceramic-based photonic nanostructures, namely photonic crystals and photonic glasses, creating so-called reflective thermal barrier coatings. In this work, mullite inverse photonic glasses (PhG) have been produced by thermally induced reaction on sol–gel-based silica structures coated with nanometric films of Al2O3 by atomic layer deposition. The conversion to mullite was carried out following a two-stage heat-treatment. The pre-annealing associated with the further mullite formation results in an excellent structural stability of these PhGs up to 1500 °C, being able to retain their high reflectivity in the near infrared range. Therefore, this structure can be considered for next-generation reflective thermal barrier coatings. Graphical abstract