Chemical etching of metals generally brings about undesirable surface damage accompanied by deteriorated performance. However, new possibilities in view of structured interfaces and functional surfaces can be explored by wisely incorporating corrosion chemistry. Here, an ultrafast route to scalable Al foils with desired porous structures originating from Fe(III)-induced oxidation etching was presented. Coupling with efficient electron polarization involving microwave interaction, straightforward surface engineering is well established on various commercial Al foils within minutes, which can be successfully extended to bulk Al alloys. As a proof-of-concept demonstration, the well-defined porous Al foils featuring regulated surface energy, demonstrate great potential as current collectors in promoting cycling stability, for example, 85.2% reversible capacity sustained after 550 cycles (comparable to commercial Al/C foils), and energy density, that is, approximately 3 times of that by using pristine Al foils for LiFePO4-Li half cells.
Keywords: electron polarization; microwave-assisted synthesis; oxidative etching; porous metal; surface engineering.