Grain boundary formation through particle detachment during coarsening of nanoporous metals

Grain boundary formation during coarsening of nanoporous gold (NPG) is investigated wherein a nanocrystalline structure can form by particles detaching and reattaching to the structure. MicroLaue and electron backscatter diffraction measurements demonstrate that an in-grain orientation spread develops as NPG is coarsened. The volume fraction of the NPG sample is near the limit of bicontinuity, at which simulations predict that a bicontinuous structure begins to fragment into independent particles during coarsening. Phase-field simulations of coarsening using a computationally generated structure with a volume fraction near the limit of bicontinuity are used to model particle detachment rates. This model is tested by using the measured NPG structure as an initial condition in the phase-field simulations. We predict that up to ∼5% of the NPG structure detaches as a dealloyed Ag75Au25 sample is annealed at 300 °C for 420 min. The quantity of volume detached is found to be highly dependent on the volume fraction and volume fraction homogeneity of the nanostructure. As the void phase in the experiments cannot support independent particles, they must fall and reattach to the structure, a process that results in the formation of new grain boundaries. This particle reattachment process, along with other classic processes, leads to the formation of grain boundaries during coarsening in nanoporous metals. The formation of grain boundaries can impact a variety of applications, including mechanical strengthening; thus, the consideration and understanding of particle detachment phenomena are essential when studying nanoporous metals.

Nanoporous metals are prototypical bicontinuous structures with a network of pores and ligaments. They are created by a number of metallic dealloying processes (1–6) allowing nearly any bulk metal to be transformed into a bicontinuous two-phase mixture of metal and void phase (7). These metals have a large interfacial area per volume enabling exciting applications in oxygen reduction (8), electromechanical devices (9), battery electrodes (10), actuators (11), and catalysts (12). Given the large surface area per volume, nanoporous structures frequently undergo coarsening when annealed at elevated temperatures. Nanoporous metals coarsen by surface diffusion (13–15), a process where the characteristic length, L, increases in time, t, according to the power law L∼t1/4 (16). Coarsening decreases the total interfacial energy of the structure, which greatly affects its material properties. For instance, coarsening is used to select the length scale in the structure, which alters the sizes of pores and ligaments (7, 17–20), ultimately impacting optical, chemical, and mechanical properties (21, 22), such as the elastic modulus (23). Nanoporous gold (NPG) often serves as a prototype for studying nanoporous metals (7). This paper investigates grain boundary formation as NPG coarsens and shows that the formation of a significant number of these boundaries is from particle detachment and subsequent reattachment.Metallic samples prior to dealloying have grain sizes on the order of 10 to 100 μm (24). Dealloying and annealing of bulk nanoporous metals are typically believed to preserve the grain orientation of the original metallic sample. This was demonstrated through electron backscatter diffraction (EBSD) measurements (1) and scanning electron microscopy (SEM) images (25) for NPG. However, these techniques provide information only about the external surfaces, not the bulk structure. The formation of an in-grain orientation spread would demonstrate that nanoporous metals can develop nanocrystallinity. Some recent work has observed a developed nanocrystalline structure in nanoporous metallic samples after dealloying and annealing. Sun et al. (26) observed grain boundary formation during annealing of NPG but assumed that the varying orientations formed due to the small grain size in the original alloy. High-resolution transmission electron microscopy (HRTEM) (27) and X-ray diffraction (28) were used to identify a nanocrystalline structure in NPG postdealloying. Nanocrystalline structures have also been identified in nanoporous platinum (29) and copper (30) postdealloying. Theories of how these grain boundaries form during dealloying and annealing have not been fully investigated. Dealloyed NPG samples have been shown to contain lattice dislocations (24). It is possible that there are driving forces for dislocations to form low-angle grain boundaries in the structure when coarsening at elevated temperatures.Coarsening of nanoporous metals is often compared to simulations that coarsen computationally generated (CG) bicontinuous structures, e.g., those formed in simulations of spinodal decomposition (31). Evolution of these structures has been studied with phase-field (31–35) and kinetic Monte Carlo (KMC) (36–38) methods. In certain volume fraction ranges, particle detachment is observed during simulations of coarsening, altering the topology of the structure. This breaking of ligaments in the structure is due to a Rayleigh–Plateau instability (38), the same mechanism causing ligament pinch-off (a ligament breaking in one place) during coarsening of nanoporous metals (13, 39, 40). The topology of an object in three dimensions (3D) is quantified by the Betti numbers: β0, the number of independent objects; β1, the number of handles (genus); and β2, the number of enclosed voids in the structure. Assuming no enclosed voids, the Euler characteristic of a 3D structure is given by χ=β0−β1 (41). When a particle detaches from the microstructure, β0 increases by 1. As particles detach from the end of ligaments, β1 remains the same. If a ligament breaks in one place (a process that is referred to as a ligament pinch-off), β1 decreases by 1 and β0 remains the same. Here we define particle detachment as the process of creating small (in size when compared to the main bicontinuous structure) isolated bodies.Simulations have demonstrated that the topology of a structure has a strong dependence on the minority phase volume fraction, ϕ, and can vary drastically within a small range of ϕ (34, 38). Using KMC, Li et al. (38) investigated coarsening via surface diffusion of structures initialized as leveled Gaussian random fields with ϕ of 22, 25, and 27% and increments of 5% from 30 to 50%. By investigating the topology, they found that structures with a ϕ lower than 30% are evolving toward a particle-dominated system, while structures with a ϕ higher than 40% are evolving as a fully connected system (β0=1). As the topological changes are related to how particles detach, we establish two regimes of topological evolution. In the particle-dominated regime (low ϕ), the structure evolves toward a state where the number of handles (β1) is either zero or low compared to the number of particles (β0). In the ligament-dominated regime (high ϕ), the structure evolves toward a state where there is a low number of particles (β0) compared to the number of handles (β1). In between these regimes (intermediate ϕ), the structure evolves to a state with an intermediate number of particles and handles, and any transition to the particle-dominated regime or the ligament-dominated regime occurs too slowly to be feasibly observed. We define this approximate boundary between regimes as the limit of bicontinuity, as the structure begins to break up while still maintaining a high degree of connectivity. Due to the approximate nature of this definition, a range of ϕ (e.g., 30 to 35%) may be considered to be “at” the limit of bicontinuity. We are most likely to observe particle detachment in structures with a ϕ at the limit of bicontinuity, where β0 might be stable or increasing throughout coarsening (signifying particle detachment) while a majority of the solid volume is contained in the main bicontinuous structure. Simulations with a ϕ in the range 30 to 35% have not yet been extensively studied despite the many coarsening experiments of nanoporous metals that are within this range.Experiments commonly study NPG samples with a ϕ between 25 and 36% postdealloying and report fully connected bicontinuous structures (17, 19, 20, 42–47). In this case, the minority phase volume fraction, ϕ, corresponds to the gold volume fraction. These ϕ values are just below or at the limit of bicontinuity predicted by simulation. However, the stability of the structures during coarsening is not always investigated, especially at lower ϕ. Detachment of particles from the bicontinuous structure can be kinetically inhibited due to short coarsening times or slow coarsening rates. However, experiments that coarsen NPG for sufficiently long times such that the mean ligament diameter increased by a factor of 16 have still reported fully connected bicontinuous structures (19, 20). The bicontinuity does not necessarily indicate that disconnections do not occur during the evolution; since the vapor phase cannot support independent particles, any particles that detach would presumably fall under their own weight and reattach elsewhere, leading to a fully connected bicontinuous structure and the formation of grain boundaries.As the ϕ of many NPG samples is at the limit of bicontinuity, we show that particles detach as NPG coarsens, and we hypothesize that the reattachment of particles leads to the formation of many of the grain boundaries that are observed in the microstructure. The results of microLaue and EBSD measurements of coarsened NPG samples with a ϕ at the limit of bicontinuity identify large in-grain orientation spreads that develop during coarsening. Phase-field simulations of coarsening of a CG bicontinuous structure with a ϕ at the limit of bicontinuity are conducted to investigate how particle detachment occurs in this regime. Subsequently, the morphology of the CG and NPG structures is characterized to search for evidence of particle reattachment phenomena. A coarsened NPG structure is then used as an initial condition in a phase-field simulation to observe how particle detachment would occur if the sample had continued to coarsen. These calculations that begin with the experimentally measured structure have identified the critical role of volume fraction homogeneity in particle detachment phenomena.