Ultra-low-density digitally architected carbon with a strutted tube-in-tube structure.

Porous materials with engineered stretching-dominated lattice designs, which offer attractive mechanical properties with ultra-light weight and large surface area for wide-ranging applications, have recently achieved near-ideal linear scaling between stiffness and density. Here, rather than optimizing the microlattice topology, we explore a different approach to strengthen low-density structural materials by designing tube-in-tube beam structures. We develop a process to transform fully dense, three-dimensional printed polymeric beams into graphitic carbon hollow tube-in-tube sandwich morphologies, where, similar to grass stems, the inner and outer tubes are connected through a network of struts. Compression tests and computational modelling show that this change in beam morphology dramatically slows down the decrease in stiffness with decreasing density. In situ pillar compression experiments further demonstrate large deformation recovery after 30-50% compression and high specific damping merit index. Our strutted tube-in-tube design opens up the space and realizes highly desirable high modulus-low density and high modulus-high damping material structures.

Nanoporous gold nanoleaf as tunable metamaterial.

We have studied optical properties of single-layer and multi-fold nanoporous gold leaf (NPGL) metamaterials and observed highly unusual transmission spectra composed of two well-resolved peaks. We explain this phenomenon in terms of a surface plasmon absorption band positioned on the top of a broader transmission band, the latter being characteristic of both homogeneous "solid" and inhomogeneous "diluted" Au films. The transmission spectra of NPGL metamaterials were shown to be controlled by external dielectric environments, e.g. water and applied voltage in an electrochemical cell. This paves the road to numerous functionalities of the studied tunable and active metamaterials, including control of spontaneous emission, energy transfer and many others.

Effect of Random Nanostructured Metallic Environments on Spontaneous Emission of HITC Dye.

We have studied emission kinetics of HITC laser dye on top of glass, smooth Au films, and randomly structured porous Au nanofoams. The observed concentration quenching of luminescence of highly concentrated dye on top of glass (energy transfer to acceptors) and the inhibition of the concentration quenching in vicinity of smooth Au films were in accord with our recent findings. Intriguingly, the emission kinetics recorded in different local spots of the Au nanofoam samples had a spread of the decay rates, which was large at low dye concentrations and became narrower with increase of the dye concentration. We infer that in different subvolumes of Au nanofoams, HITC molecules are coupled to the nanofoams weaker or stronger. The inhibition of the concentration quenching in Au nanofoams was stronger than on top of smooth Au films. This was true for all weakly and strongly coupled subvolumes contributing to the spread of the emission kinetics. The experimental observations were explained using theoretical model accounting for change in the Förster radius caused by the strong energy transfer to metal.

Integration of Fullerenes as Electron Acceptors in 3D Graphene Networks: Enhanced Charge Transfer and Stability through Molecular Design.

Here, we report a concept that allows the integration of the characteristic properties of [60]fullerene in 3D graphene networks. In these systems, graphene provides high electrical conductivity and surface area while fullerenes add high electron affinity. We use molecular design to optimize the interaction between 3D graphene networks and fullerenes, specifically in the context of stability and charge transfer in an electrochemical environment. We demonstrated that the capacity of the 3D graphene network is significantly improved upon the addition of C60 and C60 monoadducts by providing additional acceptor states in the form of low-lying lowest unoccupied molecular orbitals of C60 and its derivative. Guided by experimental results and first-principles calculations, we synthesized and tested a C60 monoadduct with increased stability by strengthening the 3D graphene-C60 van-der-Waals interactions. The synthesis method and stabilization strategy presented here is expected to benefit the integration of graphene-C60 hybrid materials in solar cell and charge storage applications.

Multiscale Morphology of Nanoporous Copper Made from Intermetallic Phases.

Many application-relevant properties of nanoporous metals critically depend on their multiscale architecture. For example, the intrinsically high step-edge density of curved surfaces at the nanoscale provides highly reactive sites for catalysis, whereas the macroscale pore and grain morphology determines the macroscopic properties, such as mass transport, electrical conductivity, or mechanical properties. In this work, we systematically study the effects of alloy composition and dealloying conditions on the multiscale morphology of nanoporous copper (np-Cu) made from various commercial Zn-Cu precursor alloys. Using a combination of X-ray diffraction, electron backscatter diffraction, and focused ion beam cross-sectional analysis, our results reveal that the macroscopic grain structure of the starting alloy surprisingly survives the dealloying process, despite a change in crystal structure from body-centered cubic (Zn-Cu starting alloy) to face-centered cubic (Cu). The nanoscale structure can be controlled by the acid used for dealloying with HCl leading to a larger and more faceted ligament morphology compared to that of H3PO4. Anhydrous ethanol dehydrogenation was used as a probe reaction to test the effect of the nanoscale ligament morphology on the apparent activation energy of the reaction.

Engineering on-chip nanoporous gold material libraries via precision photothermal treatment.

Libraries of nanostructured materials on a single chip are a promising platform for high throughput and combinatorial studies of structure-property relationships in the fields of physics and biology. Nanoporous gold (np-Au), produced by an alloy corrosion process, is a nanostructured material specifically suited for such studies because of its self-similar thermally induced coarsening behavior. However, traditional heat application techniques for the modification of np-Au are bulk processes that cannot be used to generate a library of different pore sizes on a single chip. Here, laser micro-processing offers an attractive solution to this problem by providing a means to apply energy with high spatial and temporal resolution. In the present study we use finite element multiphysics simulations to predict the effects of laser mode (continuous-wave vs. pulsed) and thermal conductivity of the supporting substrate on the local np-Au film temperatures during photothermal annealing. Based on these results we discuss the mechanisms by which the np-Au network is coarsened. Thermal transport simulations predict that continuous-wave mode laser irradiation of np-Au thin films on a silicon substrate supports the widest range of morphologies that can be created through photothermal annealing of np-Au. Using the guidance provided by simulations, we successfully fabricate an on-chip material library consisting of 81 np-Au samples of 9 different morphologies for use in the parallel study of structure-property relationships.

In Situ Real-Time Radiographic Study of Thin Film Formation Inside Rotating Hollow Spheres.

Hollow spheres with uniform coatings on the inner surface have applications in optical devices, time- or site-controlled drug release, heat storage devices, and target fabrication for inertial confinement fusion experiments. The fabrication of uniform coatings, which is often critical for the application performance, requires precise understanding and control over the coating process and its parameters. Here, we report on in situ real-time radiography experiments that provide critical spatiotemporal information about the distribution of fluids inside hollow spheres during uniaxial rotation. Image analysis and computer fluid dynamics simulations were used to explore the effect of liquid viscosity and rotational velocity on the film uniformity. The data were then used to demonstrate the fabrication of uniform sol-gel chemistry derived porous polymer films inside 2 mm inner diameter diamond shells.

Nanoporous gold as a neural interface coating: effects of topography, surface chemistry, and feature size.

Designing neural interfaces that maintain close physical coupling of neurons to an electrode surface remains a major challenge for both implantable and in vitro neural recording electrode arrays. Typically, low-impedance nanostructured electrode coatings rely on chemical cues from pharmaceuticals or surface-immobilized peptides to suppress glial scar tissue formation over the electrode surface (astrogliosis), which is an obstacle to reliable neuron-electrode coupling. Nanoporous gold (np-Au), produced by an alloy corrosion process, is a promising candidate to reduce astrogliosis solely through topography by taking advantage of its tunable length scale. In the present in vitro study on np-Au's interaction with cortical neuron-glia co-cultures, we demonstrate that the nanostructure of np-Au achieves close physical coupling of neurons by maintaining a high neuron-to-astrocyte surface coverage ratio. Atomic layer deposition-based surface modification was employed to decouple the effect of morphology from surface chemistry. Additionally, length scale effects were systematically studied by controlling the characteristic feature size of np-Au through variations in the dealloying conditions. Our results show that np-Au nanotopography, not surface chemistry, reduces astrocyte surface coverage while maintaining high neuronal coverage and may enhance neuron-electrode coupling through nanostructure-mediated suppression of scar tissue formation.

Potential-induced electronic structure changes in supercapacitor electrodes observed by in operando soft X-ray spectroscopy.

The dynamic physiochemical response of a functioning graphene-based aerogel supercapacitor is monitored in operando by soft X-ray spectroscopy and interpreted through ab initio atomistic simulations. Unanticipated changes in the electronic structure of the electrode as a function of applied voltage bias indicate structural modifications across multiple length scales via independent pseudocapacitive and electric double layer charge storage channels.

Structural optimization of 3D porous electrodes for high-rate performance lithium ion batteries.

Much progress has recently been made in the development of active materials, electrode morphologies and electrolytes for lithium ion batteries. Well-defined studies on size effects of the three-dimensional (3D) electrode architecture, however, remain to be rare due to the lack of suitable material platforms where the critical length scales (such as pore size and thickness of the active material) can be freely and deterministically adjusted over a wide range without affecting the overall 3D morphology of the electrode. Here, we report on a systematic study on length scale effects on the electrochemical performance of model 3D np-Au/TiO2 core/shell electrodes. Bulk nanoporous gold provides deterministic control over the pore size and is used as a monolithic metallic scaffold and current collector. Extremely uniform and conformal TiO2 films of controlled thickness were deposited on the current collector by employing atomic layer deposition (ALD). Our experiments demonstrate profound performance improvements by matching the Li(+) diffusivity in the electrolyte and the solid state through adjusting pore size and thickness of the active coating which, for 200 µm thick porous electrodes, requires the presence of 100 nm pores. Decreasing the thickness of the TiO2 coating generally improves the power performance of the electrode by reducing the Li(+) diffusion pathway, enhancing the Li(+) solid solubility, and minimizing the voltage drop across the electrode/electrolyte interface. With the use of the optimized electrode morphology, supercapacitor-like power performance with lithium-ion-battery energy densities was realized. Our results provide the much-needed fundamental insight for the rational design of the 3D architecture of lithium ion battery electrodes with improved power performance.

Ultra-strong and low-density nanotubular bulk materials with tunable feature sizes.

The synthesis of ultralow-density (>5 mg/cm(3) ) bulk materials with interconnected nanotubular morphology and deterministic, fully tunable feature size, composition, and density is presented. A thin-walled nanotubular design realized by employing templating based on atomic layer deposition makes the material about 10 times stronger and stiffer than aerogels of the same density.

Ultralight, ultrastiff mechanical metamaterials.

The mechanical properties of ordinary materials degrade substantially with reduced density because their structural elements bend under applied load. We report a class of microarchitected materials that maintain a nearly constant stiffness per unit mass density, even at ultralow density. This performance derives from a network of nearly isotropic microscale unit cells with high structural connectivity and nanoscale features, whose structural members are designed to carry loads in tension or compression. Production of these microlattices, with polymers, metals, or ceramics as constituent materials, is made possible by projection microstereolithography (an additive micromanufacturing technique) combined with nanoscale coating and postprocessing. We found that these materials exhibit ultrastiff properties across more than three orders of magnitude in density, regardless of the constituent material.

Photothermal laser microsintering of nanoporous gold.

Photothermal processing of nanoporous gold using a microfocused continuous-wave laser at a wavelength of 532 nm and a 1/e(2) spot diameter of 2.9 µm has been studied. In addition, complementary experiments have been carried out via conventional annealing. Scanning electron microscopy has been used for characterization. Local laser irradiation at distinct laser powers and pulse lengths results in coarsening of the porous gold structures. During laser processing the pore size of the native nanoporous gold increases to maximum values in the range of 0.25-3 µm. The affected areas exhibit lateral dimensions in the range of 2-10 µm. Overall two regions are distinguished. An inner region, where large pores and ligaments are formed and an outer region, where the pore size and ligament size gradually change and approach the feature sizes of the native material. A qualitative thermokinetic model allows one to reproduce the experimentally observed dependence of the laser-induced morphologies on the laser parameters. On the basis of this model the underlying processes are attributed to sintering and melting of the gold structures. The presented results demonstrate the prospects of photothermal laser processing in engineering porous gold with spatially varying porosities on micrometer to nanometer length scales.

Atomic layer deposition-derived ultra-low-density composite bulk materials with deterministic density and composition.

A universal approach for on-demand development of monolithic metal oxide composite bulk materials with air-like densities (<5 mg/cm(3)) is reported. The materials are fabricated by atomic layer deposition of titania (TiO2) or zinc oxide (ZnO) using the nanoscale architecture of 1 mg/cm(3) SiO2 aerogels formed by self-organization as a blueprint. This approach provides deterministic control over density and composition without affecting the nanoscale architecture of the composite material that is otherwise very difficult to achieve. We found that these materials provide laser-to-X-ray conversion efficiencies of up to 5.3%, which is the highest conversion efficiency yet obtained from any foam-based target, thus opening the door to a new generation of highly efficient laser-induced nanosecond scale multi-keV X-ray sources.

ALD functionalized nanoporous gold: thermal stability, mechanical properties, and catalytic activity.

Nanoporous metals have many technologically promising applications, but their tendency to coarsen limits their long-term stability and excludes high temperature applications. Here, we demonstrate that atomic layer deposition (ALD) can be used to stabilize and functionalize nanoporous metals. Specifically, we studied the effect of nanometer-thick alumina and titania ALD films on thermal stability, mechanical properties, and catalytic activity of nanoporous gold (np-Au). Our results demonstrate that even only 1 nm thick oxide films can stabilize the nanoscale morphology of np-Au up to 1,000°C, while simultaneously making the material stronger and stiffer. The catalytic activity of np-Au can be drastically increased by TiO(2) ALD coatings. Our results open the door to high-temperature sensor, actuator, and catalysis applications and functionalized electrodes for energy storage and harvesting applications.

Effect of surface chemistry on the stability of gold nanostructures.

Understanding the role of surface chemistry in the stability of nanostructured noble-metal materials is important for many technological applications but experimentally difficult to access and thus little understood. To develop a fundamental understanding of the effect of surface chemistry on both the formation and stabilization of self-organized gold nanostructures, we performed a series of controlled-environment annealing experiments on nanoporous gold (np-Au) and ion-bombarded Au(111) single-crystal surfaces. The annealing experiments on np-Au in ambient ozone were carried out to study the effect of adsorbed oxygen under dynamic conditions, whereas the ion-bombarded Au single-crystal surfaces were used as a model system to obtain atomic-scale information. Our results show that adsorbed oxygen stabilizes nanoscale gold structures at low temperatures whereas oxygen-induced mobilization of Au surface atoms seems to accelerate the coarsening under dynamic equilibrium conditions at higher temperatures.

Structure of incommensurate gold sulfide monolayer on Au(111).

We develop an atomic-scale model for an ordered incommensurate gold sulfide (AuS) adlayer which has previously been demonstrated to exist on the Au(111) surface, following sulfur deposition and annealing to 450 K. Our model reproduces experimental scanning tunneling microscopy images. Using state-of-the-art Wannier-function-based techniques, we analyze the nature of bonding in this structure and provide an interpretation of the unusual stoichiometry of the gold sulfide layer. The proposed structure and its chemistry have implications for related S-Au interfaces, as in those involved in self-assembled monolayers of thiols on Au substrates.