Ultrafast, Controllable Synthesis of Sub-Nano Metallic Clusters through Defect Engineering.

Supported metallic nanoclusters (NCs, < 2 nm) are of great interests in various catalytic reactions with enhanced activities and selectivities, yet it is still challenging to efficiently and controllably synthesize ultrasmall NCs with a high-dispersal density. Here we report the in situ synthesis of surfactant-free, ultrasmall, and uniform NCs via a rapid thermal shock on defective substrates. This is achieved by using high-temperature synthesis with extremely fast kinetics while limiting the synthesis time down to milliseconds (e.g., ∼1800 K for 55 ms) to avoid aggregation. Through defect engineering and optimized loading, the particle size can be robustly tuned from >50 nm nanoparticles to <1 nm uniform NCs with a high-dispersal density. We demonstrate that the ultrasmall NCs exhibit drastically improved activities for catalytic CO oxidation as compared to their nanoparticulated counterparts. In addition, the reported method shows generality in synthesizing most metallic NCs (e.g., Pt, Ru, Ir, Ni) in an extremely facile and efficient manner. The ultrafast and controllable synthesis of uniform, high-density, and size-controllable NCs paves the way for the utilization and nanomanufacturing of NCs for a range of catalytic reactions.

Carbothermal shock synthesis of high-entropy-alloy nanoparticles.

The controllable incorporation of multiple immiscible elements into a single nanoparticle merits untold scientific and technological potential, yet remains a challenge using conventional synthetic techniques. We present a general route for alloying up to eight dissimilar elements into single-phase solid-solution nanoparticles, referred to as high-entropy-alloy nanoparticles (HEA-NPs), by thermally shocking precursor metal salt mixtures loaded onto carbon supports [temperature ~2000 kelvin (K), 55-millisecond duration, rate of ~105 K per second]. We synthesized a wide range of multicomponent nanoparticles with a desired chemistry (composition), size, and phase (solid solution, phase-separated) by controlling the carbothermal shock (CTS) parameters (substrate, temperature, shock duration, and heating/cooling rate). To prove utility, we synthesized quinary HEA-NPs as ammonia oxidation catalysts with ~100% conversion and >99% nitrogen oxide selectivity over prolonged operations.

In Situ High Temperature Synthesis of Single-Component Metallic Nanoparticles.

Nanoparticles (NPs) dispersed within a conductive host are essential for a range of applications including electrochemical energy storage, catalysis, and energetic devices. However, manufacturing high quality NPs in an efficient manner remains a challenge, especially due to agglomeration during assembly processes. Here we report a rapid thermal shock method to in situ synthesize well-dispersed NPs on a conductive fiber matrix using metal precursor salts. The temperature of the carbon nanofibers (CNFs) coated with metal salts was ramped from room temperature to ∼2000 K in 5 ms, which corresponds to a rate of 400,000 K/s. Metal salts decompose rapidly at such high temperatures and nucleate into metallic nanoparticles during the rapid cooling step (cooling rate of ∼100,000 K/s). The high temperature duration plays a critical role in the size and distribution of the nanoparticles: the faster the process is, the smaller the nanoparticles are, and the narrower the size distribution is. We also demonstrated that the peak temperature of thermal shock can reach ∼3000 K, much higher than the decomposition temperature of many salts, which ensures the possibility of synthesizing various types of nanoparticles. This universal, in situ, high temperature thermal shock method offers considerable potential for the bulk synthesis of unagglomerated nanoparticles stabilized within a matrix.

Ultra-fast self-assembly and stabilization of reactive nanoparticles in reduced graphene oxide films.

Nanoparticles hosted in conductive matrices are ubiquitous in electrochemical energy storage, catalysis and energetic devices. However, agglomeration and surface oxidation remain as two major challenges towards their ultimate utility, especially for highly reactive materials. Here we report uniformly distributed nanoparticles with diameters around 10 nm can be self-assembled within a reduced graphene oxide matrix in 10 ms. Microsized particles in reduced graphene oxide are Joule heated to high temperature (∼1,700 K) and rapidly quenched to preserve the resultant nano-architecture. A possible formation mechanism is that microsized particles melt under high temperature, are separated by defects in reduced graphene oxide and self-assemble into nanoparticles on cooling. The ultra-fast manufacturing approach can be applied to a wide range of materials, including aluminium, silicon, tin and so on. One unique application of this technique is the stabilization of aluminium nanoparticles in reduced graphene oxide film, which we demonstrate to have excellent performance as a switchable energetic material.