Metallic foams, with intrinsic catalytic properties, are critical for heterogeneous catalysis reactions and reactor designs. Market ready catalytic foams are costly and made of multimaterial coatings with large sub-millimeter open cells providing insufficient active surface area. Here we use the principle of nanometallurgy within liquid metals to prepare nanostructured catalytic metal foams using a low-cost alloy of bismuth and tin with sub-micrometer open cells. The eutectic bismuth and tin liquid metal alloy was processed into nanoparticles and blown into a tin and bismuth nanophase separated heterostructure in aqueous media at room temperature and using an indium brazing agent. The CO2 electroconversion efficiency of the catalytic foam is presented with an impressive 82% conversion efficiency toward formates at high current density of -25 mA cm-2 (-1.2 V vs RHE). Nanometallurgical process applied to liquid metals will lead to exciting possibilities for expanding industrial and research accessibility of catalytic foams.
Keywords: CO2 electro-conversion; inorganic foam; metal foam; metal nanoparticle; nanobrazing; nanometallurgy.