Synthesis and characterization of the dealloyed hierarchical structure of AlSi10Mg-Cu alloys prepared using laser-powder bed fusion

Abstract Nanoporous structures with high surface area can be obtained by 3D printing of lattice structures and subsequent dealloying, with potential applications in the field of catalysis and batteries. Here we prepared a AlSi10Mg-Cu (38wt%) alloy by laser-powder bed fusion of mixed powders. A metastable structure was obtained after 3D printing, with significant differences in solidification structures in different regions. The solidification structure is inherited after dealloying, in which dendrites form submicron ligaments, and nanoscale ligaments are formed inside the dendrites. Dealloying of a 3D-printed lattice structure allows the preparation of hierarchical nanoporous copper with only limited crack formation.