Template-free electrochemical synthesis of tin nanostructures

One-dimensional (1D) nanostructures, often referred to as nanowires, have attracted considerable attention due to their unique mechanical, chemical, and electrical properties. Although numerous novel technological applications are being proposed for these structures, many of the processes used to synthesize these materials involve a vapor phase and require high temperatures and long growth times. Potentially faster methods requiring templates, such as anodized aluminum oxide, involve multiple fabrication steps, which would add significantly to the cost of the final material and may preclude their widespread use. In the present study, it is shown that template-free electrodeposition from an alkaline solution can produce arrays of Sn nanoneedles directly onto Cu foil substrates. This electrodeposition process occurs at 55 °C; it is proposed that the nanoneedles grow via a catalyst-mediated mechanism. In such a process, the growth is controlled at the substrate/nanostructure interface rather than resulting from random plating-induced defects such as dendrites or aging defects such as tin whiskers. There are multiple potential applications for 1D Sn nanostructures—these include anodes in lithium-ion and magnesium-ion batteries and as thermal interface materials. To test this potential, type 2032 lithium-ion battery button cells were fabricated using the electrodeposited Sn. These cells showed initial capacities as high as 850 mAh/g and cycling stability for over 200 cycles.