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Abstract Thin‐film solid‐state metal dealloying (thin‐film SSMD) is a promising method for fabricating nanostructures with controlled morphology and efficiency, offering advantages over conventional bulk materials processing methods for integration into practical applications. Although machine learning (ML) has facilitated the design of dealloying systems, the selection of key thermal treatment parameters for nanostructure formation remains largely unknown and dependent on experimental trial and error. To overcome this challenge, a workflow enabling high‐throughput characterization of thermal treatment parameters is demonstrated using a laser‐based thermal treatment to create temperature gradients on single thin‐film samples of Nb‐Al/Sc and Nb‐Al/Cu. This continuous thermal space enables observation of dealloying transitions and the resulting nanostructures of interest. Through synchrotron X‐ray multimodal and high‐throughput characterization, critical transitions and nanostructures can be rapidly captured and subsequently verified using electron microscopy. The key temperatures driving chemical reactions and morphological evolutions are clearly identified. While the oxidation may influence nanostructure formation during thin‐film treatment, the dealloying process at the dealloying front involves interactions solely between the dealloying elements, highlighting the availability and viability of the selected systems. This approach enables efficient exploration of the dealloying process and validation of ML predictions, thereby accelerating the discovery of thin‐film SSMD systems with targeted nanostructures.
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Progression of the dealloying front in bilayer Cu–Al and Cu–Zn nanoporous foams
Abstract The role of interfaces and the controlling synthesis parameters of graded dealloyed nanoporous metallic materials are investigated, focusing on the dealloying front progression in complex precursor materials with multiple alloy compositions. Specifically, the effects of relative density and chemical potential on the dealloying front in sputtered bilayer copper alloy films are explored with two case studies: Cu–Al/Cu–Al and Cu–Al/Cu–Zn. Cross-sectional scanning electron (SEM) micrographs and energy-dispersive X-ray spectroscopy mapping trace the dealloying front across three time intervals, while top-surface and cross-sectional SEM probes the final dealloyed foam morphology. Final ligament sizes were found to be independent of the synthesis parameters (21–28 nm), due to a combination of fast reaction times and phosphate-inhibited surface diffusion of Cu atoms. The chemical potential gradient yielded faster reaction times, whereas slower reaction times and a higher at.% of Cu in the top layer of precursor material produced a more uniform morphology. Graphical abstract
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- Award ID(s):
- 2106597
- PAR ID:
- 10419290
- Publisher / Repository:
- Cambridge University Press (CUP)
- Date Published:
- Journal Name:
- Journal of Materials Research
- Volume:
- 38
- Issue:
- 13
- ISSN:
- 0884-2914
- Page Range / eLocation ID:
- p. 3407-3415
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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