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A study of the stability of bicontinuous nanoporous metals is presented. Atomic scale simulations are used to probe the dominant mechanisms of geometric relaxation in these materials. A method is presented for generating model bicontinuous metal / void structures for use in atomistic simulations of bicontinuous nanoporous solids. The structures are generated with periodic boundary conditions using a phase-field model to simulate the spinodal decomposition of an ideal system. One phase in the model is then associated with the pore volume while the other phase is associated with the metal ligaments. Small angle neutron scattering was used to quantitatively compare experimental samples to those generated by the phase field method. EAM results using model structures with experimentally accessible length scales are presented which demonstrate the potential of such simulations in understanding the behavior of nanoporous metals. Simulated relaxations of these structures, as well as the relaxation of model spherical clusters, indicate that the surface relaxation effect dominates the overall dimensional relaxation of np-metals post processing. Capillary effects play a secondary role in the overall relaxation. The simulation results presented also identify a maximum surface area to volume ratio necessary to maintain mechanical stability beyond which the pore structure collapses. / Ph. D.

Polymer electrolyte fuel cells (PEFCs) have emerged as a promising renewable emission-free technology to solve the worldwide increasing demand for clean and efficient energy conversion. Despite large efforts in academia and automotive industry, the commercialization of PEFC vehicles still remains a great challenge. Critical issues are high material costs, insufficient catalytic activity as well as longterm durability. Especially due to the sluggish kinetics of the oxygen reduction reaction (ORR), high Pt loadings on the cathode are still necessary which leads to elevated costs. Alloys of Pt with other less precious metals (Co, Ni, Fe, Cu, etc.) show improved ORR activities compared to pure Pt catalysts. However, state-of-the-art carbon-supported catalysts suffer from severe Pt and carbon corrosion during the standard operation of PEFCs, affecting their reliability and long-term efficiency. Multimetallic aerogels constitute excellent candidates to overcome these issues. Due to their large open pores and high inner surface areas combined with electrical conductivity, they are ideal for applications in electrocatalysis. In addition, they can be employed without any catalyst support. Therefore, the fabrication of bimetallic Pt-M (M=Ni, Cu, Co, Fe) aerogels for applications in fuel cell catalysis was the focus of this thesis. Based on a previously published synthesis for Pt–Pd aerogels, a facile one-step procedure at ambient conditions in aqueous solution was developed. Bimetallic aerogels with nanochain diameters of as small as 4 nm and Brunauer-Emmett-Teller (BET) surface areas of up to 60 m2/g could be obtained. Extensive structure analysis of Pt–Ni and Pt–Cu aerogels by powder X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), X-ray absorption spectroscopy (XAS), scanning transmission electron microscopy coupled with energy-dispersive X-ray spectroscopy (STEM-EDX) and electrochemical techniques showed that both metals were predominantly present in their metallic state and formed homogeneous alloys. However, metal (hydr)oxide byproducts were observed in aerogels with higher contents of non-precious metal (>25 %). Moreover, electronic and geometric structures were similar to those of carbon-supported Pt alloy catalysts. As a result, ORR activites were comparable, too. A threefold improvement in surface-specific activity over Pt/C catalysts was achieved. The mass-specific activites met or exceeded the U.S. Department of Energy (DOE) target for automotive PEFC applications. Furthermore, a direct correlation between non-precious metal content in the alloy and ORR activity was discovered. Aerogels with nonprecious metal contents >25% turned out to be susceptible to dealloying in acid leaching experiments, but there was no indication for the formation of extended surface structures like Pt-skeletons. A Pt3Ni aerogel was successfully employed as the cathode catalyst layer in a differential fuel cell (1 cm2), which is a crucial step towards technical application. This was the first time an unsupported metallic aerogel was implemented in a PEFC. Accelerated stress tests that are usually applied to investigate the support stability of fuel cell catalysts revealed the excellent stability of Pt3Ni alloyed aerogels. In summary, the Pt alloy aerogels prepared in the context of this work have proven to be highly active oxygen reduction catalysts with remarkable stability.

Selective dissolution also known as dealloying is a corrosion process in which one component of a binary alloy system is selectively removed through an electrochemically controlled process which leads to the formation of a porous metal "sponge" with a porosity that is completely interconnected and random in direction. Nanoporous metals are desirable since they have larger surface areas than an equal volume of non-porous material. Because of their enormous surface area per volume, these highly porous metal electrodes are superior materials for high surface area applications such as in biomedical devices, microfilters and catalysts. Understanding the kinetic processes governing the development of porosity during dealloying and having ability to change the electrochemical conditions will allow us to better control over the average ligament size and distribution in porosity. The basic kinetic processes involved in the formation of these structures are related to such issues as environmental effects and electrochemical conditions on diffusion, microscopic coarsening phenomenon at room temperature and elevated temperatures, alloy passivation, and Gibbs-Thomson effects. The average pore size and distribution was found to depend on the electrolyte composition, dealloying rate, applied potential and time. The porosity was found to significantly coarsen at room temperature during the dealloying process and this coarsening was highly dependent on the applied potential. It is showed that the commonly accepted measurement of the critical potential for alloy dissolution calculated based on extrapolation of anodic polarization data results in an overestimation of this quantity. A series of constant applied potential experiments prove to be a more accurate method for critical potential determination. / Ph. D.

New challenges in nanotechnology arise in the assembly of nanoobjects into three-dimensional superstructures, which may carry synergetic properties and open up new application fields. Within this new class of materials nanostructured, porous functional metals are of great interest since they combine high surface area, gas permeability, electrical conductivity, plasmonic behavior and size-enhanced catalytic reactivity. Even though a large variety of preparation pathways for the fabrication of porous noble metals has already been established, several limitations are still to be addressed by research developments. The new and versatile approach that is presented in this work makes use of a templatefree self-assembly process for the fabrication of highly porous, metallic nanostructures. Thereby, nanochains are formed by the controlled coalescence of noble metal NPs in aqueous media and their interconnection and interpenetration leads to the formation of a self-supported network with macroscopic dimensions. Subsequently, the supercritical drying technique is used to remove the solvent from the pores of the network without causing a collapse of the fragile structure. The resulting highly porous, low-weighted, three-dimensional nanostructured solids are named aerogels. The exceptional properties of these materials originate from the conjunction of the unique properties of nanomaterials magnified by macroscale assembly. Moreover, the combination of different metals may lead to synergetic effects regarding for example their catalytic activity. Therefore, the synthesis of multimetallic gels and the characterization of their structural peculiarities are in the focus of the investigations. In the case of the developed preparation pathways the gelation process starts from preformed, stable colloidal solutions of citrate capped, spherical noble metal (Au, Ag, Pt, Pd) NPs. In order to face various requirements several methods for the initiation of the controlled destabilization and coalescence of the nanosized building blocks were developed and synthesis conditions were optimized, respectively. Multimetallic structures with tunable composition are obtained by mixing different kinds of monometallic NP solutions and performing a joint gel formation. The characterization of the resulting materials by means of electron microscopy reveals the formation of a highly porous network of branched nanochains that provide a polycrystalline nature and diameters in the size range of the initial NPs. Furthermore, synthesis conditions for the spontaneous gel formation of glucose stabilized Au and Pd NPs were investigated. In order to gain a detailed knowledge of the structural properties of bimetallic aerogel structures a versatile set of characterization techniques was applied. A broad pore size distribution dominated by meso- and macropores and remarkably high inner surface areas were concluded from the N2 physisorption isotherms and density measurements. As investigated, a specific thermal treatment could be used to tune the ligament size of Au-Ag aerogels, whereas Au-Pd and Pt-Pd structures provide thermal stability under mild conditions. Further investigations aimed to the enlightenment of the elemental distribution and phase composition within the nanochains of multimetallic gel structures. The different approaches provide complementary and consistent results. Phase analyses based on XRD measurements revealed separated phases of each metal in the case of Ag-Pd and Au-Pd aerogels. They further proved the possibility of temperature induced phase modifications that lead to complete alloying of Au and Pd. In addition, separated domains of Pt and Pd were established from the EXAFS analysis of the corresponding aerogel. STEM EDX high resolution elemental mappings confirmed the separated domains of different metals in the case of Au-Pd and Pt-Pd aerogels. Moreover, a complete interdiffusion and alloy formation of Au and Ag within the corresponding aerogel structure is suggested from STEM EDX results. Finally, the presented investigations further promote the field of metallic aerogels by addressing the challenging issue of processability and device fabrication. Hybrid materials with organic polymers as well as various kinds of coatings on glass substrates and glassy carbon electrodes were prepared whereas the network structure was preserved throughout all processing steps. Moreover, it was illustrated that the NP-based aerogels carry metallic properties as expressed by their low Seebeck coefficients and high electrical conductivities.

Polymer electrolyte fuel cells (PEFCs) have emerged as a promising renewable emission-free technology to solve the worldwide increasing demand for clean and efficient energy conversion. Despite large efforts in academia and automotive industry, the commercialization of PEFC vehicles still remains a great challenge. Critical issues are high material costs, insufficient catalytic activity as well as longterm durability. Especially due to the sluggish kinetics of the oxygen reduction reaction (ORR), high Pt loadings on the cathode are still necessary which leads to elevated costs. Alloys of Pt with other less precious metals (Co, Ni, Fe, Cu, etc.) show improved ORR activities compared to pure Pt catalysts. However, state-of-the-art carbon-supported catalysts suffer from severe Pt and carbon corrosion during the standard operation of PEFCs, affecting their reliability and long-term efficiency. Multimetallic aerogels constitute excellent candidates to overcome these issues. Due to their large open pores and high inner surface areas combined with electrical conductivity, they are ideal for applications in electrocatalysis. In addition, they can be employed without any catalyst support. Therefore, the fabrication of bimetallic Pt-M (M=Ni, Cu, Co, Fe) aerogels for applications in fuel cell catalysis was the focus of this thesis. Based on a previously published synthesis for Pt–Pd aerogels, a facile one-step procedure at ambient conditions in aqueous solution was developed. Bimetallic aerogels with nanochain diameters of as small as 4 nm and Brunauer-Emmett-Teller (BET) surface areas of up to 60 m2/g could be obtained. Extensive structure analysis of Pt–Ni and Pt–Cu aerogels by powder X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), X-ray absorption spectroscopy (XAS), scanning transmission electron microscopy coupled with energy-dispersive X-ray spectroscopy (STEM-EDX) and electrochemical techniques showed that both metals were predominantly present in their metallic state and formed homogeneous alloys. However, metal (hydr)oxide byproducts were observed in aerogels with higher contents of non-precious metal (>25 %). Moreover, electronic and geometric structures were similar to those of carbon-supported Pt alloy catalysts. As a result, ORR activites were comparable, too. A threefold improvement in surface-specific activity over Pt/C catalysts was achieved. The mass-specific activites met or exceeded the U.S. Department of Energy (DOE) target for automotive PEFC applications. Furthermore, a direct correlation between non-precious metal content in the alloy and ORR activity was discovered. Aerogels with nonprecious metal contents >25% turned out to be susceptible to dealloying in acid leaching experiments, but there was no indication for the formation of extended surface structures like Pt-skeletons. A Pt3Ni aerogel was successfully employed as the cathode catalyst layer in a differential fuel cell (1 cm2), which is a crucial step towards technical application. This was the first time an unsupported metallic aerogel was implemented in a PEFC. Accelerated stress tests that are usually applied to investigate the support stability of fuel cell catalysts revealed the excellent stability of Pt3Ni alloyed aerogels. In summary, the Pt alloy aerogels prepared in the context of this work have proven to be highly active oxygen reduction catalysts with remarkable stability.

Experiments on the production of porous metallic materials were performed on Fe-base and Al-base alloys. The method involves dissolution of gases in the liquid state and solidification at various cooling rates. The alloy compositions were selected to induce solidification of primary particles intended to control the pore distribution. For the Fe-base alloys, nitrogen was introduced into the melt by dissolution of chromium nitride powder. Fe-Cr-Mn-Si-C alloys featuring M7C3 carbide particles were selected. For the Al-base alloys, hydrogen gas was dissolved into the melt by decomposition of water vapor. Al-Ti and Al-Fe alloys featuring primary Al3Ti and Al3Fe intermetallic particles, respectively, were considered. In the Fe-base alloys, a homogeneous distribution of gas pores through the specimens’ volume was obtained at high cooling rate (water quenching) and after introduction of external nucleating agents. In the case of the Al-base alloys, a good pore distribution was observed at all cooling rates and without addition of nucleating agents. Calculations of the variation of nitrogen (respectively hydrogen) solubility based on Wagner interaction parameters suggest that pore nucleation and growth occur during precipitation of the primary particles (M7C3 carbides, Al3Ti or Al3Fe intermetallics), due to composition changes in the melt and resultant supersaturation with gas atoms. Microscopic analyses revealed that the primary particles control the pore growth in the melt and act as barriers between adjacent pores, thereby preventing pore coalescence and promoting a fine pore distribution. Uniaxial compression testing of the porous Al-Ti and Al-Fe materials showed the typical compressive behavior of cellular metals. Further work is needed to improve the quality and reproducibility of the porous structures which can possibly be used in energy absorption or load-bearing applications. As a corollary result of the quenching of hypereutectic Fe-Cr-Mn-Si-C alloys in the experiments of synthesis of porous metals, a homogeneous featureless structure was observed in some parts of the samples, instead of the equilibrium structure of M7C3 and eutectic phases. Subsequent investigations on rapid solidification of Fe-base alloys at various alloy compositions and cooling rates led to the formation of a single-phase structure for the composition Fe-8Cr-6Mn-5Mo-5Si-3.2C (wt.%), at relatively low cooling rates (≈103 K/s) and for large sample dimensions (2.85 mm). The single phase, which is likely to be the hcp ɛ-phase, was found to decompose into a finely distributed structure of bainite and carbides at ≈600 °C. The annealed structure showed very high hardness values (850 to 1200 HV), which could be exploited in the development of high-strength Fe-base materials. / QC 20100809

New challenges in nanotechnology arise in the assembly of nanoobjects into three-dimensional superstructures, which may carry synergetic properties and open up new application fields. Within this new class of materials nanostructured, porous functional metals are of great interest since they combine high surface area, gas permeability, electrical conductivity, plasmonic behavior and size-enhanced catalytic reactivity. Even though a large variety of preparation pathways for the fabrication of porous noble metals has already been established, several limitations are still to be addressed by research developments. The new and versatile approach that is presented in this work makes use of a templatefree self-assembly process for the fabrication of highly porous, metallic nanostructures. Thereby, nanochains are formed by the controlled coalescence of noble metal NPs in aqueous media and their interconnection and interpenetration leads to the formation of a self-supported network with macroscopic dimensions. Subsequently, the supercritical drying technique is used to remove the solvent from the pores of the network without causing a collapse of the fragile structure. The resulting highly porous, low-weighted, three-dimensional nanostructured solids are named aerogels. The exceptional properties of these materials originate from the conjunction of the unique properties of nanomaterials magnified by macroscale assembly. Moreover, the combination of different metals may lead to synergetic effects regarding for example their catalytic activity. Therefore, the synthesis of multimetallic gels and the characterization of their structural peculiarities are in the focus of the investigations. In the case of the developed preparation pathways the gelation process starts from preformed, stable colloidal solutions of citrate capped, spherical noble metal (Au, Ag, Pt, Pd) NPs. In order to face various requirements several methods for the initiation of the controlled destabilization and coalescence of the nanosized building blocks were developed and synthesis conditions were optimized, respectively. Multimetallic structures with tunable composition are obtained by mixing different kinds of monometallic NP solutions and performing a joint gel formation. The characterization of the resulting materials by means of electron microscopy reveals the formation of a highly porous network of branched nanochains that provide a polycrystalline nature and diameters in the size range of the initial NPs. Furthermore, synthesis conditions for the spontaneous gel formation of glucose stabilized Au and Pd NPs were investigated. In order to gain a detailed knowledge of the structural properties of bimetallic aerogel structures a versatile set of characterization techniques was applied. A broad pore size distribution dominated by meso- and macropores and remarkably high inner surface areas were concluded from the N2 physisorption isotherms and density measurements. As investigated, a specific thermal treatment could be used to tune the ligament size of Au-Ag aerogels, whereas Au-Pd and Pt-Pd structures provide thermal stability under mild conditions. Further investigations aimed to the enlightenment of the elemental distribution and phase composition within the nanochains of multimetallic gel structures. The different approaches provide complementary and consistent results. Phase analyses based on XRD measurements revealed separated phases of each metal in the case of Ag-Pd and Au-Pd aerogels. They further proved the possibility of temperature induced phase modifications that lead to complete alloying of Au and Pd. In addition, separated domains of Pt and Pd were established from the EXAFS analysis of the corresponding aerogel. STEM EDX high resolution elemental mappings confirmed the separated domains of different metals in the case of Au-Pd and Pt-Pd aerogels. Moreover, a complete interdiffusion and alloy formation of Au and Ag within the corresponding aerogel structure is suggested from STEM EDX results. Finally, the presented investigations further promote the field of metallic aerogels by addressing the challenging issue of processability and device fabrication. Hybrid materials with organic polymers as well as various kinds of coatings on glass substrates and glassy carbon electrodes were prepared whereas the network structure was preserved throughout all processing steps. Moreover, it was illustrated that the NP-based aerogels carry metallic properties as expressed by their low Seebeck coefficients and high electrical conductivities.