Dealloying of Mg-based alloys for production of self-supporting metallic nanostructures

Dealloying is a proficient technique in the fabrication of nanostructured metals, particularly nanoporous materials, with promising potential for diverse applications. However, the development of robust and self-standing nanostructured metal foils through dealloying presents significant challenges. By generating an alloy layer on the surface of the metal foil, nanostructures can be generated on the metal foil surface through subsequent dealloying. This approach utilizes the inherent flexibility and ductility of the metal foil to ensure self-support. It also allows for the tailoring of the structure and composition of the dealloyed nanostructured metal by manipulation of the phase constitution in the surface alloy layer. In this study, we report a strategy for generating alloy layers on metal foil surfaces through the thermal evaporation of magnesium (Mg) followed by annealing. Upon dealloying the surface alloy layer, we successfully obtain self-supported nanostructured metal foils. Employing copper (Cu) as an example, we demonstrate that Mg can form a Mg–Cu alloy layer on the surface of a Cu foil, where the control over the alloy layer`s phase composition and thickness is achieved by adjusting the annealing duration. Furthermore, we investigated the feasibility of this method on nickel (Ni) substrates, including Ni foils and Ni foams. Moreover, by further functionalizing the resulting nanostructured Ni foil, we transformed it into Ni(OH) ₂/Ni foil and explored its performance in the electrocatalytic oxygen evolution reaction (OER). The resulting catalyst achieved a current density of 10 mA cm ⁻² at a potential of only 349 mV in a 1 M KOH solution, exhibiting a Tafel slope of 84.52 mV dec ⁻¹. Following 10 h of stability testing, the catalyst exhibited negligible degradation in performance. This study provides a convenient and versatile pathway for preparing self-supported nanostructured metals.