Porous metal nitride film synthesis without template

TL;DR

This paper introduces a template-free method to synthesize highly porous metal nitride films with over 84% porosity, enhancing their mass transfer and reactivity for applications like sensing and catalysis.

Contribution

The authors develop a self-assembly based, template-free process to create highly porous metal nitride films with broad compositional versatility, improving performance over traditional methods.

Findings

Porous metal nitride films with >84% porosity were successfully synthesized.

Porous films exhibit lower resistance and higher reactivity than oxide counterparts.

Enhanced sensing performance demonstrated with a five-fold higher response to NO₂ at 75°C.

Abstract

Metal nitrides possess exceptional catalytic, electronic and physical properties making them widely used in (opto-)electronics and as hard coatings. When used as films in surface-active applications, however, their performance remains limited by poor mass transfer and reduced accessibility of reactive sites. This is associated to compact film architecture yielded by conventional deposition techniques (e.g., 16-26% for sputtered W$_2$N). Here, we demonstrate a template-free method for the design of highly porous (porosity > 84%) metal nitride films with high compositional versatility, as demonstrated for Cu3N, W2N, MoNx and TiN. These are obtained by exploiting the self-assembly of fractal-like metal oxide agglomerates during deposition from aerosols followed by their dry nitridation. In case of Cu$_3$N, monocristalline oxide nanoparticles were converted to polycrystalline nitrides during nitridation, as traced by X-ray diffraction and electron microscopy. Such films feature consistently lower resistances than their metal oxide counterparts, as well as high reactivity and mass transfer. This is exploited exemplarily for molecular sensing of NO$_2$ at only 75$^\circ$C temperature, leading to up to a five-fold higher response with faster response time over more compact spin-coated films for. As a result, our approach overcomes critical mass transfer performance limitations of metal nitride films that are also relevant for other applications like electrocatalysis and energy storage.