Datasets for the microstructure of nanoscale metal network structures and for its evolution during coarsening

Nanoporous Gold: From Structure Evolution to Functional Properties in Catalysis and Electrochemistry

Nanoporous gold (NPG) is characterized by a bicontinuous network of nanometer-sized metallic struts and interconnected pores formed spontaneously by oxidative dissolution of the less noble element from gold alloys. The resulting material exhibits decent catalytic activity for low-temperature, aerobic total as well as partial oxidation reactions, the oxidative coupling of methanol to methyl formate being the prototypical example. This review not only provides a critical discussion of ways to tune the morphology and composition of this material and its implication for catalysis and electrocatalysis, but will also exemplarily review the current mechanistic understanding of the partial oxidation of methanol using information from quantum chemical studies, model studies on single-crystal surfaces, gas phase catalysis, aerobic liquid phase oxidation, and electrocatalysis. In this respect, a particular focus will be on mechanistic aspects not well understood, yet. Apart from the mechanistic aspects of catalysis, best practice examples with respect to material preparation and characterization will be discussed. These can improve the reproducibility of the materials property such as the catalytic activity and selectivity as well as the scope of reactions being identified as the main challenges for a broader application of NPG in target-oriented organic synthesis.

Self-Detachment and Subsurface Densification of Dealloyed Nanoporous Thin Films

Experiment shows thin films of dealloyed nanoporous gold (NPG) spontaneously detaching from massive gold base layers. NPG can also densify near its external surface. This is naturally reproduced by kinetic Monte Carlo (KMC) simulation of dealloying and coarsening and so appears generic for nanoscale network materials evolving by surface diffusion. Near the porous layer's external surface and near its interface with the base layer, gradients in the depth-profile of a laterally averaged mean surface curvature provide driving forces for diffusion and cause divergences of the net fluxes of matter, leading to accretion/densification or to erosion/disconnection. As a toy model, the morphology evolution of substrate-supported nanopillars by surface diffusion illustrates and confirms our considerations. Contrary to cylindrical nanowires, the ligaments in nanoporous materials exhibit pre-existing gradients in the mean curvature. The Plateau-Rayleigh long-wavelength stability criterion is then not applicable and the disconnection accelerated.

Topological control of liquid-metal-dealloyed structures

The past few years have witnessed the rapid development of liquid metal dealloying to fabricate nano-/meso-scale porous and composite structures with ultra-high interfacial area for diverse materials applications. However, this method currently has two important limitations. First, it produces bicontinuous structures with high-genus topologies for a limited range of alloy compositions. Second, structures have a large ligament size due to substantial coarsening during dealloying at high temperature. Here we demonstrate computationally and experimentally that those limitations can be overcome by adding to the metallic melt an element that promotes high-genus topologies by limiting the leakage of the immiscible element during dealloying. We further interpret this finding by showing that bulk diffusive transport of the immiscible element in the liquid melt strongly influences the evolution of the solid fraction and topology of the structure during dealloying. The results shed light on fundamental differences in liquid metal and electrochemical dealloying and establish a new approach to produce liquid-metal-dealloyed structures with desired size and topologies.

Dilute Alloys Based on Au, Ag, or Cu for Efficient Catalysis: From Synthesis to Active Sites

The development of new catalyst materials for energy-efficient chemical synthesis is critical as over 80% of industrial processes rely on catalysts, with many of the most energy-intensive processes specifically using heterogeneous catalysis. Catalytic performance is a complex interplay of phenomena involving temperature, pressure, gas composition, surface composition, and structure over multiple length and time scales. In response to this complexity, the integrated approach to heterogeneous dilute alloy catalysis reviewed here brings together materials synthesis, mechanistic surface chemistry, reaction kinetics, in situ and operando characterization, and theoretical calculations in a coordinated effort to develop design principles to predict and improve catalytic selectivity. Dilute alloy catalysts─in which isolated atoms or small ensembles of the minority metal on the host metal lead to enhanced reactivity while retaining selectivity─are particularly promising as selective catalysts. Several dilute alloy materials using Au, Ag, and Cu as the majority host element, including more recently introduced support-free nanoporous metals and oxide-supported nanoparticle "raspberry colloid templated (RCT)" materials, are reviewed for selective oxidation and hydrogenation reactions. Progress in understanding how such dilute alloy catalysts can be used to enhance selectivity of key synthetic reactions is reviewed, including quantitative scaling from model studies to catalytic conditions. The dynamic evolution of catalyst structure and composition studied in surface science and catalytic conditions and their relationship to catalytic function are also discussed, followed by advanced characterization and theoretical modeling that have been developed to determine the distribution of minority metal atoms at or near the surface. The integrated approach demonstrates the success of bridging the divide between fundamental knowledge and design of catalytic processes in complex catalytic systems, which can accelerate the development of new and efficient catalytic processes.

In Situ Study of Nanoporosity Evolution during Dealloying AgAu and CoPd by Grazing-Incidence Small-Angle X-ray Scattering

Electrochemical dealloying has become a standard technique to produce nanoporous network structures of various noble metals, exploiting the selective dissolution of one component from an alloy. While achieving nanoporosity during dealloying has been intensively studied for the prime example of nanoporous Au from a AgAu alloy, dealloying from other noble-metal alloys has been rarely investigated in the scientific literature. Here, we study the evolution of nanoporosity in the electrochemical dealloying process for both CoPd and AgAu alloys using a combination of in situ grazing-incidence small-angle X-ray scattering (GISAXS), kinetic Monte Carlo (KMC) simulations, and scanning transmission electron microscopy (STEM). When comparing dealloying kinetics, we find a more rapid progression of the dealloying front for CoPd and also a considerably slower coarsening of the nanoporous structure for Pd in relation to Au. We argue that our findings are natural consequences of the effectively higher dealloying potential and the higher interatomic binding energy for the CoPd alloy. Our results corroborate the understanding of electrochemical dealloying on the basis of two rate equations for dissolution and surface diffusion and suggest the general applicability of this dealloying mechanism to binary alloys. The present study contributes to the future tailoring of structural size in nanoporous metals for improved chemical surface activity.

Transition from Homogeneous to Localized Deformation in Nanoporous Gold

We report a transition from homogeneous deformation to localized densification for nanoporous gold (NPG) under compression, with its solid fraction (φ) increasing to above ∼1/3. Results obtained herein suggest that this transition is inverted compared to that of conventional porous materials. Consequently, under compression, the low-density NPGs with φ<1/3 showed evident strain hardening, whereas a stress plateau was observed for high-density NPGs with φ>1/3, which is contrary to the established notions for conventional porous materials. The ligament pinch-offs and bending-dominated structures are responsible for the homogeneous deformation of low-density NPGs. For high-density NPGs, the compression- or tension-dominated structure enables the collective strain bursts in nanoligaments, resulting in localized densification and stress plateau in their compression curves. In addition to the nanosize effect, the surface-diffusion-mediated topology evolution and the large-scale crystal-lattice coherency arising from the large grain size are also decisive to the mechanical response of dealloyed NPGs, which might be universal for self-organized nanonetwork materials.

Grain boundary formation through particle detachment during coarsening of nanoporous metals

Grain boundary formation during coarsening of nanoporous gold (NPG) is investigated wherein a nanocrystalline structure can form by particles detaching and reattaching to the structure. MicroLaue and electron backscatter diffraction measurements demonstrate that an in-grain orientation spread develops as NPG is coarsened. The volume fraction of the NPG sample is near the limit of bicontinuity, at which simulations predict that a bicontinuous structure begins to fragment into independent particles during coarsening. Phase-field simulations of coarsening using a computationally generated structure with a volume fraction near the limit of bicontinuity are used to model particle detachment rates. This model is tested by using the measured NPG structure as an initial condition in the phase-field simulations. We predict that up to ∼5% of the NPG structure detaches as a dealloyed [Formula: see text] sample is annealed at 300 °C for 420 min. The quantity of volume detached is found to be highly dependent on the volume fraction and volume fraction homogeneity of the nanostructure. As the void phase in the experiments cannot support independent particles, they must fall and reattach to the structure, a process that results in the formation of new grain boundaries. This particle reattachment process, along with other classic processes, leads to the formation of grain boundaries during coarsening in nanoporous metals. The formation of grain boundaries can impact a variety of applications, including mechanical strengthening; thus, the consideration and understanding of particle detachment phenomena are essential when studying nanoporous metals.

Light, strong, and stable nanoporous aluminum with native oxide shell

Aluminum (Al) metal is highly reactive but has excellent corrosion resistance because of the formation of a self-healing passive oxide layer on the surface. Here, we report that this native aluminum oxide shell can also stabilize and strengthen porous Al when the ligament (strut) size is decreased to the submicron or nanometer scale. The nanoporous Al with native oxide shell, which is a nanoporous Al-Al₂O₃ core-shell composite self-organized in a galvanic replacement reaction, is nonflammable under ambient conditions and stable against coarsening near melting temperatures. This material is stronger than conventional foams of similar density consisting of pure Al or Al-based composites, and also lighter and stronger than most nanoporous metals reported previously. Its light weight, high strength, and excellent stability warrant the explorations of functional and structural applications of this material, if more efficient and scalable synthesis processes are developed in the future.

Formation of three-dimensional bicontinuous structures via molten salt dealloying studied in real-time by in situ synchrotron X-ray nano-tomography

Three-dimensional bicontinuous porous materials formed by dealloying contribute significantly to various applications including catalysis, sensor development and energy storage. This work studies a method of molten salt dealloying via real-time in situ synchrotron three-dimensional X-ray nano-tomography. Quantification of morphological parameters determined that long-range diffusion is the rate-determining step for the dealloying process. The subsequent coarsening rate was primarily surface diffusion controlled, with Rayleigh instability leading to ligament pinch-off and creating isolated bubbles in ligaments, while bulk diffusion leads to a slight densification. Chemical environments characterized by X-ray absorption near edge structure spectroscopic imaging show that molten salt dealloying prevents surface oxidation of the metal. In this work, gaining a fundamental mechanistic understanding of the molten salt dealloying process in forming porous structures provides a nontoxic, tunable dealloying technique and has important implications for molten salt corrosion processes, which is one of the major challenges in molten salt reactors and concentrated solar power plants.

Effect of Heat Treatment on the Microstructure and Performance of Cu Nanofoams Processed by Dealloying

Cu nanofoams are promising materials for a variety of applications, including anodes in high-performance lithium-ion batteries. The high specific surface area of these materials supports a high capacity and porous structure that helps accommodate volume expansion which occurs as batteries are charged. One of the most efficient methods to produce Cu nanofoams is the dealloying of Cu alloy precursors. This process often yields nanofoams that have low strength, thus requiring additional heat treatment to improve the mechanical properties of Cu foams. This paper provides the effects of heat treatment on the microstructures, mechanical properties, and electrochemical performance of Cu nanofoams. Annealing was conducted under both inert and oxidizing atmospheres. These studies ultimately reveal the underlying mechanisms of ligament coarsening during heat treatment.

A Strategy for Dimensionality Reduction and Data Analysis Applied to Microstructure-Property Relationships of Nanoporous Metals

Nanoporous metals, with their complex microstructure, represent an ideal candidate for the development of methods that combine physics, data, and machine learning. The preparation of nanporous metals via dealloying allows for tuning of the microstructure and macroscopic mechanical properties within a large design space, dependent on the chosen dealloying conditions. Specifically, it is possible to define the solid fraction, ligament size, and connectivity density within a large range. These microstructural parameters have a large impact on the macroscopic mechanical behavior. This makes this class of materials an ideal science case for the development of strategies for dimensionality reduction, supporting the analysis and visualization of the underlying structure-property relationships. Efficient finite element beam modeling techniques were used to generate ~200 data sets for macroscopic compression and nanoindentation of open pore nanofoams. A strategy consisting of dimensional analysis, principal component analysis, and machine learning allowed for data mining of the microstructure-property relationships. It turned out that the scaling law of the work hardening rate has the same exponent as the Young's modulus. Simple linear relationships are derived for the normalized work hardening rate and hardness. The hardness to yield stress ratio is not limited to 1, as commonly assumed for foams, but spreads over a large range of values from 0.5 to 3.

Using X-Ray Scattering to Elucidate the Microstructural Instability of 3D Bicontinuous Nanoporous Metal Scaffolds for Use in an Aperiodic 3D Tricontinuous Conductor-Insulator-Conductor Nanocapacitor

The development of three-dimensional aperiodic energy storage devices is in part impeded by the lack of appropriate aperiodic templates that can withstand the thermal conditions required to deposit energy storage materials within their void space. Herein, the feasibility of an aperiodic three-dimensional architecture for energy storage is demonstrated for the first time by constructing a tricontinuous conductor-insulator-conductor (CIC) nanocapacitor on an aperiodic nanoporous gold scaffold. To accomplish this, the scaffold was characterized using in situ small-angle X-ray scattering (SAXS) during exposure to a thermal environment, revealing that its microstructure eventually stabilizes after undergoing a phase of rapid coarsening, indicating a departure from the 1/4 time-dependent power-law coarsening behavior usually observed at the early stage of the coarsening process. Using this stability regime, we created the CIC by intentionally precoarsening and stabilizing the scaffold before depositing two dissimilar metal oxide films in its void space by atomic layer deposition. Current-voltage characteristics and electrochemical impedance spectroscopy measurements revealed that the un-optimized 3D CIC outperformed its 2D counterpart by ∼4× in terms of capacitance. This proof-of-concept device will pave the way to the development of aperiodic three-dimensional energy storage systems with enhanced energy and power densities.

Annealing-Induced Changes in the Microstructure and Mechanical Response of a Cu Nanofoam Processed by Dealloying

Cu nanoporous foams are promising candidates for use as an anode material for advanced lithium ion batteries. In this study, Cu nanofoam was processed from pack-cemented bulk material via dealloying. In the as-processed Cu nanofoam, the average ligament size was ~105 nm. The hardness in this initial state was ~2 MPa, and numerous cracks were observed in the indentation pattern obtained after hardness testing, thus indicating the low mechanical strength of the material. Annealing for 6 h under an Ar atmosphere at 400 °C was shown to result in crystalline coarsening and a reduction in the probability of twin faulting in the ligaments. Simultaneously, the junctions of the ligaments became stronger and hence more difficult to crack. This study demonstrates that moderate heat treatment under Ar can improve the resistance against crack propagation in Cu nanofoam without a large change in the ligament size and the surface oxide content, which can thus influence the electrochemical performance of the material in battery applications.

A Review of Experimentally Informed Micromechanical Modeling of Nanoporous Metals: From Structural Descriptors to Predictive Structure-Property Relationships

Nanoporous metals made by dealloying take the form of macroscopic (mm- or cm-sized) porous bodies with a solid fraction of around 30%. The material exhibits a network structure of "ligaments" with an average ligament diameter that can be adjusted between 5 and 500 nm. Current research explores the use of nanoporous metals as functional materials with respect to electrochemical conversion and storage, bioanalytical and biomedical applications, and actuation and sensing. The mechanical behavior of the network structure provides the scope for fundamental research, particularly because of the high complexity originating from the randomness of the structure and the challenges arising from the nanosized ligaments, which can be accessed through an experiment only indirectly via the testing of the macroscopic properties. The strength of nanoscale ligaments increases systematically with decreasing size, and owing to the high surface-to-volume ratio their elastic and plastic properties can be additionally tuned by applying an electric potential. Therefore, nanoporous metals offer themselves as suitable model systems for exploring the structure-property relationships of complex interconnected microstructures as well as the basic mechanisms of the chemo-electro-mechanical coupling at interfaces. The micromechanical modeling of nanoporous metals is a rapidly growing field that strongly benefits from developments in computational methods, high-performance computing, and visualization techniques; it also benefits at the same time through advances in characterization techniques, including nanotomography, 3D image processing, and algorithms for geometrical and topological analysis. The review article collects articles on the structural characterization and micromechanical modeling of nanoporous metals and discusses the acquired understanding in the context of advancements in the experimental discipline. The concluding remarks are given in the form of a summary and an outline of future perspectives.

Datasets for the microstructure of nanoscale metal network structures and for its evolution during coarsening

The datasets in this work are files containing atom position coordinates of volume elements approximating nanoporous gold made by dealloying and annealing. The material is represented in an as-prepared state and in various stages of coarsening, as described in Phys. Rev. Mater, 3 (2019) 076001. Realistic initial structures of different solid fractions have been constructed by the leveled-wave algorithm, approximating mixtures at the end of early-stage spinodal decomposition. The microstructural evolution during coarsening by surface diffusion was approximated by on-lattice kinetic Monte-Carlo simulation. The data sets refer to solid fractions from 0.22 to 0.50, providing for different initial connectivity of the bicontinuous structures. Coarsening at two temperatures, 900 K and 1800 K, explores two different degrees of surface energy anisotropy – more faceted at 900 K and more rough at 1800 K. Each structure takes the form of a face-centred cubic lattice with approximately 32 million sites. A site can be occupied by either void or atom. 3D periodic boundary conditions are satisfied. Tables list each structure's properties, and specifically the specific surface area, two different measures for the ligament size, the net topological genus as well as the scaled genus. The atom coordinate files may serve as the basis for geometry analysis and for atomistic as well as finite element simulation studies of nanoporous as well as spinodally decomposed materials. The data sets are accessible via the TORE repository at http://hdl.handle.net/11420/3253.