Solid‐state metal dealloying (SSMD) is a promising method for fabricating nanoscale metallic composites and nanoporous metals across a range of materials. Thin‐film SSMD is particularly attractive due to its ability to create fine features via solid‐state interfacial reactions within a thin‐film geometry, which can be integrated into devices for various applications. This work examines a new dealloying couple, namely the Nb–Al alloy with the dealloying agent Sc, as previously predicted in the machine‐learning (ML) models. Prior ML predictions aimed to guide the design of nanoarchitectured materials through dealloying, relying on intuition‐driven discovery within a large parameter space. However, this work reveals that at the nanoscale, the involvement of oxygen in thin film processing may instead drive the dealloying process, resulting in the formation of bicontinuous nanostructures similar to those formed by metal‐agent dealloying. The phase evolution, as well as chemical and morphological changes, are closely analyzed using a combination of X‐ray absorption spectroscopy, diffraction, and scanning transmission electron microscopy to understand the mechanisms behind nanostructure formation. The findings suggest a potential pathway for utilizing oxygen to drive the formation of bicontinuous metal–metal oxide nanocomposites, paving the way for further development of functional nanoporous materials in diverse fields.
- Award ID(s):
- 1752839
- NSF-PAR ID:
- 10319057
- Date Published:
- Journal Name:
- Nanoscale
- Volume:
- 13
- Issue:
- 42
- ISSN:
- 2040-3364
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract -
Bicontinuous-nanostructured materials with a three-dimensionally (3D) interconnected morphology offer unique properties and potential applications in catalysis, biomedical sensing and energy storage. The new approach of solid-state interfacial dealloying (SSID) opens a route for fabricating bi-continuous metal–metal composites and porous metals at nano-/meso-scales via a self-organizing process driven by minimizing the system's free energy. Integrating SSID and thin film processing fully can open up a wide range of technological opportunities in designing novel functional materials; to-date, no experimental evidence has shown that 3D bi-continuous films can be formed with SSID, owing to the complexity of the kinetic mechanisms in thin film geometry and at nano-scales, despite the simple processing strategy in SSID. Here, we demonstrate that a fully-interconnected 3D bi-continuous structure can be achieved by this new approach, thin-film-SSID, using Fe–Ni film dealloyed by Mg film. The formation of a Fe–Mg x Ni bi-continuous 3D nano-structure was visualized and characterized via a multi-scale, multi-modal approach, combining electron transmission microscopy with synchrotron X-ray fluorescence nano-tomography and absorption spectroscopy. Phenomena involved with structural formation are discussed. These include surface dewetting, nano-size void formation among metallic ligaments, and interaction with a substrate. This work sheds light on the mechanisms of the SSID process, and sets a path for manufacturing of thin-film materials for future nano-structured metallic materials.more » « less
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Abstract Machine learning-augmented materials design is an emerging method for rapidly developing new materials. It is especially useful for designing new nanoarchitectured materials, whose design parameter space is often large and complex. Metal-agent dealloying, a materials design method for fabricating nanoporous or nanocomposite from a wide range of elements, has attracted significant interest. Here, a machine learning approach is introduced to explore metal-agent dealloying, leading to the prediction of 132 plausible ternary dealloying systems. A machine learning-augmented framework is tested, including predicting dealloying systems and characterizing combinatorial thin films via automated and autonomous machine learning-driven synchrotron techniques. This work demonstrates the potential to utilize machine learning-augmented methods for creating nanoarchitectured thin films.
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Abstract Intermetallic compounds formed from non-precious transition metals are promising cost-effective and robust catalysts for electrochemical hydrogen production. However, the development of monolithic nanoporous intermetallics, with ample active sites and sufficient electrocatalytic activity, remains a challenge. Here we report the fabrication of nanoporous Co7Mo6and Fe7Mo6intermetallic compounds via liquid metal dealloying. Along with the development of three-dimensional bicontinuous open porosity, high-temperature dealloying overcomes the kinetic energy barrier, enabling the direct formation of chemically ordered intermetallic phases. Unprecedented small characteristic lengths are observed for the nanoporous intermetallic compounds, resulting from an intermetallic effect whereby the chemical ordering during nanopore formation lowers surface diffusivity and significantly suppresses the thermal coarsening of dealloyed nanostructure. The resulting ultrafine nanoporous Co7Mo6exhibits high catalytic activity and durability in electrochemical hydrogen evolution reactions. This study sheds light on the previously unexplored intermetallic effect in dealloying and facilitates the development of advanced intermetallic catalysts for energy applications.
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Porous metals and alloys, such as those fabricated via electrochemical dealloying, are of interest for a variety of energy applications, ranging from their potential for enhanced catalytic behavior to their use as high surface area supports for pseudocapacitor materials. Here, the electrochemical dealloying process was explored for electrodeposited binary NiCo and ternary NiCoCu thin films. For each of the four different metal ratios, films were dealloyed using linear sweep voltammetry to various potentials in order to gain insight into the evolution of the film over the course of the linear sweep. Electrochemical capacitance, scanning electron microscopy, and energy dispersive X-ray spectroscopy were used to examine the structure and composition of each sample before and after linear sweep voltammetry was performed. For NiCo films, dealloying resulted in almost no change in composition but did result in an increased capacitance, with greater increases occurring at higher linear sweep potentials, indicating the removal of material from the films. Dealloying also resulted in the appearance of large pores on the surface of the high nickel percentage NiCo films, while low nickel percentage NiCo films had little observable change in morphology. For NiCoCu films, Cu was almost completely removed at linear sweep potentials greater than 0.5 V versus Ag/AgCl. The linear sweep removed large Cu-rich dendrites from the films, while also causing increases in measured capacitance.more » « less
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1039/D1NR03709A
