Fabrication of porous and nanoporous aluminum via selective dissolution of Al-Zn alloys

Abstract

Porous and nanoporous aluminum have been fabricated via selective dissolution. Al-Zn alloys were dealloyed in an aqueous solution of nitric acid to selectively dissolve zinc. Fast solidification methods permitted to adjust the precursor microstructure of the parent alloy in order to induce supersaturation of zinc in aluminum. An electric potential applied during corrosion affected the final morphology of porosity. Electronic imaging evinced the presence of regions with less than 100 nm diameter pores. This nanoporosity was only present in electrochemically dealloyed samples. We observed two types of porosity in dealloyed samples: a primary porosity resulting from the selective removal of zinc-rich interdendritic phases and a secondary porosity resulting from nanoporosity evolution inside zinc-supersaturated dendrites.