AbstractLow‐shrinkage porous mullite–zirconia ceramics were prepared using Al and ZrSi2 as raw materials and AlF3 as the whisker catalyst through foam‐gelcasting and freeze‐drying methods. The oxidation of Al and ZrSi2 combined with the Kirkendall effect and volume expansion was employed to reduce the sintering shrinkage, while the mullitization was promoted by the reaction between AlF3 and extra ZrSi2, and ZrO2 were generated to enhance the compressive strength as the reinforcing phase. The effect of AlF3 and ZrSi2 content on the microstructure and properties of porous mullite‐zirconia were explored. These ceramics exhibited high porosity (73.75%–85.02%) and compressive strength (2.98–17.71 MPa), low shrinkage (0.47%–10.89%) and thermal conductivity (0.228–0.462 W/(m·K)). In particular, the porous mullite–zirconia ceramics with great compressive strength (4.01 MPa) companied with near‐zero shrinkage (0.47%) at the AlF3 content of 15 wt% and extra ZrSi2 content of 20 wt% by introducing the reinforcing phase (ZrO2). Additionally, the temperature difference around 950°C of the porous ceramics during the heating test proved the exceptional application on thermal insulation.
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