Search for: All records

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 

Abstract The effect of target geometry on coating microstructure and morphology is correlated to changes in deposition conditions, plasma characteristics, and film growth during planar and hollow cathode sputtering. The sputtering plasma properties for the two target geometries were characterized via Langmuir probe analysis as a function of power density and Ar pressure to determine the evolution of ion density for each configuration. Films were then synthesized at the low (0.4 W cm⁻²) and high (1.2 W cm⁻²) power densities and characterized using x-ray diffraction, scanning electron microscopy, and electron backscatter diffraction to link changes in texturing, morphology, and microstructure with variations in ion density and sputtering deposition conditions caused by target geometry. It was observed that varying target geometry led to an over threefold increase in deposition rate, homologous temperature, and ion density, which altered the morphology and texture of the film without significant changes to the grain size. 

The microstructural transformations of binary nanometallic multilayers (NMMs) to equiaxed nanostructured materials were explored by characterizing a variety of nanoscale multilayer films. Four material systems of multilayer films, Hf-Ti, Ta-Hf, W-Cr, and Mo-Au, were synthesized by magnetron sputtering, heat treated at 1000 °C, and subsequently characterized by transmission electron microscopy. Binary systems were selected based on thermodynamic models predicting stable nanograin formation with similar global compositions around 20–30 at.%. All NMMs maintained nanocrystalline grain sizes after evolution into an equiaxed structure, where the systems with highly mobile incoherent interfaces or higher energy interfaces showed a more significant increase in grain size. Furthermore, varying segregation behaviors were observed, including grain boundary (GB) segregation, precipitation, and intermetallic formation depending on the material system selected. The pathway to tailored microstructures was found to be governed by key mechanisms and factors as determined by a film’s initial characteristics, including global and local composition, interface energy, layer structure, and material selection. This work presents a global evaluation of NMM systems and demonstrates their utility as foundation materials to promote tailored nanomaterials.