Self-assembled porous metal-intermetallic nanocomposites via liquid metal dealloying

A major challenge in the synthesis of high surface area metals via subtractive processes such as dealloying is maintaining the mechanical integrity of the resulting porous materials. This problem is especially apparent in liquid metal dealloying, in which high-temperature selective dissolution in a molten metal bath leads to bicontinuous porosity formation. In liquid metal dealloying of polycrystalline alloys, grain boundary separation leads to the detachment of individual grains. In this work, we show that addition of small amounts of silicon to Nb–Ti or Ta–Ti parent alloys leads to the generation of self-assembled arrays of intermetallic (niobium silicide or tantalum silicide) plates that are structurally merged with the usual bicontinuous porosity seen in dealloying. These silicide plates pass through grain boundaries and hold the niobium or tantalum network intact without strongly affecting the microstructural evolution during dealloying. Our approach yields a mechanically robust porous metal-intermetallic composite, which can be further processed to form tertiary materials via re-impregnation by a new third phase. The materials design strategy introduced here can be generalized to serve as a platform to form dense multiphase nanocomposites.