Bulk gold with hierarchical macro-, micro- and nano-porosity

Millimeter-sized, free-standing gold structures were created with three levels of multiscale porosity. First, macro- and microporosity, which are useful for mass and heat transport within the structure, are formed within an Ag–19 at.% Au alloy by salt powder replication during powder densification and by entrapped gas expansion during sintering, respectively. Nanoporosity, which provides high surface area, is then produced by silver dealloying of these Ag–19 at.% Au foams. The resulting hierarchical gold structures are annealed at 100–800 °C, thus coarsening the ligaments, increasing relative density, and healing cracks produced during dealloying. The first effect weakens the structure, while the other two make it stronger. A bulk Au sample with hierarchical porosity annealed at 600 °C shows good compressive ductility and a strength in agreement with models.