Formation of nanoporous copper through dealloying of dual-phase Cu-Mn-Al alloy: The evolution of microstructure and composition

A freestanding bulk nanoporous copper with ultralow density has been fabricated through dealloying of as-cast dual-phase Cu1Mn1Al8 alloy, and the dealloying behavior was investigated systematically. The experimental results show that due to different electrochemical activities, the Al11Cu5Mn3 phase of the dual-phase precursor alloy dissolved before AlCu2Mn, which corresponds to the dramatical evolutions of microstructure and composition. Additionally, a formation pattern based upon a mechanism combined “dissolution-redeposition” pattern, “phase-separation” pattern, and “coarsening” process has been built to describe the evolution process, which includes four stages, sequentially defined as “dissolution of Al11Cu5Mn3,” “redeposition of Cu atoms,” “dealloying of AlCu2Mn,” and “coarsening.”