A method is provided for producing insulation materials and insulation for high temperature applications using novel castable and powder-based ceramics. The ceramic components produced using the proposed process offers (i) a fine porosity (from nano-to micro scale); (ii) a superior strength-to-weight ratio; and (iii) flexibility in designing multilayered features offering multifunctionality which will increase the service lifetime of insulation and refractory components used in the solid oxide fuel cell, direct carbon fuel cell, furnace, metal melting, glass, chemical, paper/pulp, automobile, industrial heating, coal, and power generation industries. Further, the ceramic components made using this method may have net-shape and/or net-size advantages with minimum post machining requirements.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
This invention was made in part with government support under Contract No.: DE-FG02-03ER83619 awarded by the Department of Energy and Contract/Award No.: DMI-0321692, awarded by the National Science Foundation. The Government has certain rights in the inventions.