Fabrication of nanoporous metal electrode by two-step replication technique

Nanoporous Ni metal membrane was fabricated by using nano-technique (two-step replication) from porous anodic alumina (PAA) template. In the first step replication, poly(methyl methacrylate) (PMMA) with various concentrations and molecular weights was filled into PAA mother template to obtain PMMA negative-type cylindrical structure. The results indicate that the increasing concentration and molecular weight of PMMA is required to fabricate satisfactory PMMA negative-type cylindrical structure due to the higher intermolecular interaction of molecular chains. The higher intermolecular interaction provided better strength to maintain the desired PMMA negative-type cylindrical structure. In the second step replication, Ni was electrochemically deposited into the PMMA cylindrical structure. After removing PMMA by acetone, nanoporous Ni metal membrane was obtained. The morphology of nanoporous Ni membrane was similar to that of PAA mother template. A film of yittria-stabilized zirconia (YSZ) electrolyte can be finally deposited on the Ni metal membrane by EPD process. This metal membrane might be used as an electrode in the applications of solid electrochemical devices.