LAUSR

Abstract This study demonstrated the synthesis of novel zirconium pyrophosphate (ZrP2O7) ceramic foams via a two-step method using a foam casting technique. The synthesised foams functioned as thermal insulators with a highly controllable performance. We investigated the effects of the addition of foaming and thickening agents as well as the solid content of the slurries on the slurry, mechanical properties, thermal conductivities, and microstructure of ZrP2O7 ceramic foams. The ZrP2O7 ceramic foams synthesised at 1473 K exhibited a porosity, compressive strength, and thermal conductivity of 75.2–89.1 %, 1.95–0.02 MPa, and 0.144–0.057 W/(m K) (298–573 K), respectively. The increase in the porosity to >60 % will facilitate applications based on the low thermal conductivities of the foams.