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.