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High temperature synthesis and treatments are ubiquitous in chemical reactions and material manufacturing. However, conventional sintering furnaces are bulky and inefficient with a narrow temperature range (<1500 K) and slow heating rates (<100 K min⁻¹), which are undesirable for many applications that require transient heating to produce ideal nanostructures. Herein, a 3D‐printed, miniaturized reactor featuring a dense micro‐grid design is developed to maximize the material contact and therefore acheive highly efficient and controllable heating. By 3D printing, a versatile, miniaturized reactor with microscale features can be constructed, which can reach a much wider temperature range (up to ≈3000 K) with ultrafast heating/cooling rates of ≈10⁴K s⁻¹. To demonstrate the utility of the design, rapid and batch synthesis of Ru nanoparticles supported in ordered mesoporous carbon is performed by transient heating (1500 K, 500 ms). The resulting ultrafine and uniform Ru nanoparticles (≈2 nm) can serve as a cathode in Li‐CO₂batteries with good cycling stability. The miniaturized reactor, with versatile shape design and highly controllable heating capabilities, provides a platform for nanocatalyst synthesis with localized and ultrafast heating toward high temperatures that is otherwise challenging to achieve.

 

Efficient electrocatalysts are critical in various clean energy conversion and storage systems. Polyelemental nanomaterials are attractive as multifunctional catalysts due to their wide compositions and synergistic properties. However, controlled synthesis of polyelemental nanomaterials is difficult due to their complex composition. Herein, a one‐step synthetic strategy is presented to fabricate a hierarchical polyelemental nanomaterial, which contains ultrasmall precious metal nanoparticles (IrPt, ≈5 nm) anchored on spinel‐structure transition metal oxide nanoparticles. The polyelemental nanoparticles serve as excellent bifunctional catalysts for the oxygen evolution reaction (OER) and oxygen reduction reaction (ORR). The mass catalytic activity of the polyelemental nanoparticles is 7‐times higher than that of Pt in ORR and 28‐times that of Ir in OER at the same overpotentials, demonstrating the high activity of the bifunctional electrocatalyst. This outstanding performance is attributed to the controlled multiple elemental composition, mixed chemical states, and large electroactive surface area. The hierarchical nanostructure and polyelemental design of these nanoparticles offer a general and powerful alternative material for catalysis, solar cells, and more.

 

The interaction between metal nanoparticles (NPs) and their substrate plays a critical role in determining the particle morphology, distribution, and properties. The pronounced impact of a thin oxide coating on the dispersion of metal NPs on a carbon substrate is presented. Al₂O₃‐supported Pt NPs are compared to the direct synthesis of Pt NPs on bare carbon surfaces. Pt NPs with an average size of about 2 nm and a size distribution ranging between 0.5 nm and 4.0 nm are synthesized on the Al₂O₃coated carbon nanofiber, a significant improvement compared to those directly synthesized on a bare carbon surface. First‐principles modeling verifies the stronger adsorption of Pt clusters on Al₂O₃than on carbon, which attributes the formation of ultrafine Pt NPs. This strategy paves the way towards the rational design of NPs with enhanced dispersion and controlled particle size, which are promising in energy storage and electrocatalysis.

 

Supported bimetallic alloy nanoparticles are of great interest in various catalytic applications due to the synergistic effects between different metals for improved catalytic performance. However, it still remains a challenge to efficiently synthesize atomically mixed alloy nanoparticles with uniform dispersion onto a desired substrate. Here, in situ, rapid synthesis of atomically mixed bimetallic nanoparticles well‐dispersed on a conductive carbon network via a 1 s high‐temperature pulse (HTP, ≈1550 K, duration 1 s, the rate of 10⁴K s⁻¹) is reported. The high temperature facilitates the total (atomic) mixing of different metals, while the rapid quenching ensures the uniform dispersion of nanoparticles with fine features such as twin boundaries and stacking faults, which are potentially beneficial to their catalytic performance. By varying the ratio of the precursor salts and parameters in the HTP process, the composition, size, and morphology of the resultant nanoparticles can easily be tuned. Moreover, the synthesized bimetallic (PdNi) nanoparticles demonstrate excellent electrocatalytic performance for the hydrogen evolution reaction and hydrogen peroxide electrooxidation. This work provides a general strategy for a facile and rapid synthesis of bimetallic nanoparticles directly from their salts for a range of emerging applications.

 

A review highlights improvements in synthesizing and stabilizing multielement nanoparticles. 

Abstract Direct formation of ultra-small nanoparticles on carbon supports by rapid high temperature synthesis method offers new opportunities for scalable nanomanufacturing and the synthesis of stable multi-elemental nanoparticles. However, the underlying mechanisms affecting the dispersion and stability of nanoparticles on the supports during high temperature processing remain enigmatic. In this work, we report the observation of metallic nanoparticles formation and stabilization on carbon supports through in situ Joule heating method. We find that the formation of metallic nanoparticles is associated with the simultaneous phase transition of amorphous carbon to a highly defective turbostratic graphite (T-graphite). Molecular dynamic (MD) simulations suggest that the defective T-graphite provide numerous nucleation sites for the nanoparticles to form. Furthermore, the nanoparticles partially intercalate and take root on edge planes, leading to high binding energy on support. This interaction between nanoparticles and T-graphite substrate strengthens the anchoring and provides excellent thermal stability to the nanoparticles. These findings provide mechanistic understanding of rapid high temperature synthesis of metal nanoparticles on carbon supports and the origin of their stability.