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<p>It remains a major challenge to enhance the mechanical robustness of alumina aerogels (AA) without compromising their ultralow thermal conductivity. Herein, an alumina source previously obtained through calcination activation and acid leaching of coal gangue (CG) was utilized in this study, and carbon-fiber-reinforced CG-based alumina aerogel composites (CAA) were successfully fabricated via a sol–gel process combined with ambient pressure drying (APD). Carbon fibers are uniformly and randomly distributed within the AA matrix, forming a distinctive three-dimensional network structure. The resulting composites exhibit a density of 0.213–0.326&#xa0;g/cm<sup>3</sup>, a specific surface area of 46.02–178.11&#xa0;m<sup>2</sup>/g, and excellent thermal insulation performance with thermal conductivities ranging from 0.042 to 0.050&#xa0;W&#xa0;m<sup>−1</sup>&#xa0;K<sup>−1</sup>. More importantly, the incorporation of carbon fibers significantly enhances the mechanical properties of the aerogels. CAA sample with dimensions of Ø45&#xa0;mm × 10&#xa0;mm and a mass of 4.27&#xa0;g can support a load of 6350&#xa0;g, which is approximately 1487 times its own weight. The compressive strength reaches 4.81–6.99&#xa0;MPa under 80% strain, representing an improvement of approximately 125–226% over pure AA. Meanwhile, the compressive modulus increases to 33.37–40.20&#xa0;MPa, corresponding to an enhancement of 55–87% compared with pure AA. This study demonstrates that the incorporation of carbon fibers into AA effectively enhances their mechanical robustness and thermal insulation performance, and provides a practical strategy to improve the performance of AA-based insulation materials.</p> Graphical abstract <p></p>

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Carbon fiber-reinforced alumina aerogels from coal gangue: a synergistic strategy for enhanced mechanical and thermal insulation properties

  • 期刊论文

  • 发表日期：

    2026年4月5日

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  • Bin Huang,
  • Ye Zhou,
  • Khomidov Fakhriddin Gafurovich,
  • Kadyrova Zulayho Raimovna,
  • Linqiang Mao,
  • Bingying Gao

摘要

It remains a major challenge to enhance the mechanical robustness of alumina aerogels (AA) without compromising their ultralow thermal conductivity. Herein, an alumina source previously obtained through calcination activation and acid leaching of coal gangue (CG) was utilized in this study, and carbon-fiber-reinforced CG-based alumina aerogel composites (CAA) were successfully fabricated via a sol–gel process combined with ambient pressure drying (APD). Carbon fibers are uniformly and randomly distributed within the AA matrix, forming a distinctive three-dimensional network structure. The resulting composites exhibit a density of 0.213–0.326 g/cm3, a specific surface area of 46.02–178.11 m2/g, and excellent thermal insulation performance with thermal conductivities ranging from 0.042 to 0.050 W m−1 K−1. More importantly, the incorporation of carbon fibers significantly enhances the mechanical properties of the aerogels. CAA sample with dimensions of Ø45 mm × 10 mm and a mass of 4.27 g can support a load of 6350 g, which is approximately 1487 times its own weight. The compressive strength reaches 4.81–6.99 MPa under 80% strain, representing an improvement of approximately 125–226% over pure AA. Meanwhile, the compressive modulus increases to 33.37–40.20 MPa, corresponding to an enhancement of 55–87% compared with pure AA. This study demonstrates that the incorporation of carbon fibers into AA effectively enhances their mechanical robustness and thermal insulation performance, and provides a practical strategy to improve the performance of AA-based insulation materials.

Graphical abstract