Soft Chemistry of Hard Materials: Low-Temperature Pathways to Bulk and Nanostructured Layered Metal Borides.

Conspectus"Synthesis by design" is often considered to be the primary goal of chemists who make molecules and materials. Synthetic chemists usually have in mind a target they want to make, and they want to be able to design a pathway that can get them to that target as quickly and efficiently as possible. Chemists who synthesize refractory solids, which have melting points above 1000 °C and are often chemically inert at these high temperatures, have access to only a small number of synthetic strategies due to the need to overcome solid-state diffusion, which is the rate-limiting step in such reactions. The use of extremely high temperatures to facilitate diffusion among two or more refractory solids, which precedes any chemical reaction that must occur, generally drives the system to form only the product that is the most thermodynamically stable-the global minimum on an energy landscape-for a certain combination of elements. When trying to target a different product in the same system, one generally cannot rely on thermally driven reactions. Lower-temperature reactions that side step this diffusion limitation can succeed where high temperatures fail by providing access to local minima on an energy landscape. These local minima represent metastable phases that are primed for synthesis, but only if an appropriate pathway and set of reactions can be identified. It is therefore important to develop and understand low-temperature, or "soft", chemical reactions in "hard" refractory systems. These reactions allow us to apply the retrosynthetic framework that molecular chemists rely on to systems where chemists have not previously had such control over reactions, reactivities, and metastable product formation.In this Account, we discuss the development of soft chemical reactions of hard materials in the context of a class of layered, refractory metal borides that are precursors to an emerging family of two-dimensional nanomaterials. Layered ternary metal boride phases such as MoAlB have layers of metal borides, which are chemically unreactive, interleaved with layers of aluminum, which are reactive. Some of the interlayer aluminum can be deintercalated at room temperature in dilute aqueous sodium hydroxide, transforming stable MoAlB into destabilized MoAl1-xB. Mild thermal treatment of submicrometer grains of this destabilized MoAl1-xB sample allows it to traverse the energy landscape and crystallize as Mo2AlB2, a metastable compound. Further thermal treatment transforms Mo2AlB2 into a Mo2AlB2-alumina nanolaminate and ultimately mesoporous MoB, all through continued traversing of the energy landscape using mild chemical and thermal treatments. Similar topochemical manipulations, which maintain structure but change composition, are emerging for other MAB phases and are opening the door to new types of metastable compounds and nanostructured materials in traditionally refractory systems.

Introducing Porosity into Refractory Molybdenum Boride through Controlled Decomposition of a Metastable Mo-Al-B Precursor.

The high temperatures typically required to synthesize refractory compounds preclude the formation of high-energy morphological features, including nanoscopic pores that are beneficial for applications, such as catalysis, that require higher surface areas. Here, we demonstrate a low-temperature multistep pathway to engineer mesoporosity into a catalytic refractory material. Mesoporous molybdenum boride, α-MoB, forms through the controlled thermal decomposition of nanolaminate-containing sheets of the metastable MAB (metal-aluminum-boron) phase Mo2AlB2 and amorphous alumina. Upon heating, the Mo2AlB2 layers of the Mo2AlB2-AlOx nanolaminate, which is derived from MoAlB, begin to bridge and decompose, forming inclusions of alumina in a framework of α-MoB. The alumina can be dissolved in aqueous sodium hydroxide in an autoclave, forming α-MoB with empty and accessible pores. Statistical analysis of the morphologies and dimensions of the pores reveals a correlation with grain size, which relates to the pathway by which the alumina inclusions form. The transformation of Mo2AlB2 to α-MoB is topotactic due to crystal structure relationships, resulting in a high density of stacking faults that can be modeled to account for the observed experimental diffraction data. Porosity was validated by comparing surface areas and demonstrating catalytic viability for the hydrogen evolution reaction.

Emergence and Control of Stacking Fault Formation during Nanoparticle Cation Exchange Reactions.

Cation exchange reactions modify the composition of a nanocrystal while retaining other features, including the crystal structure and morphology. In many cases, the anion sublattice is considered to be locked in place as cations rapidly shuttle in and out. Here we provide evidence that the anion sublattice can shift significantly during nanocrystal cation exchange reactions. When the Cu+ cations of roxbyite Cu1.8S nanorods exchange with Zn2+ to form ZnS nanorods, a high density of stacking faults emerges. During cation exchange, the stacking sequence of the close-packed anion sublattice shifts at many locations to generate a nanorod product containing a mixture of wurtzite, zincblende, and a wurtzite/zincblende polytype that contains an ordered arrangement of stacking faults. The reagent concentration and reaction temperature, which control the cation exchange rate, serve as synthetic levers that can tune the stacking fault density from high to low, which is important because once introduced, the stacking faults could not be modified through thermal annealing. This level of synthetic control through nanocrystal cation exchange is important for controlling properties that depend on the presence and density of stacking faults.

Multi-Step Topochemical Pathway to Metastable Mo2AlB2 and Related Two-Dimensional Nanosheet Heterostructures.

The rational synthesis of metastable inorganic solids, which is a grand challenge in solid-state chemistry, requires the development of kinetically controlled reaction pathways. Topotactic strategies can achieve this goal by chemically modifying reactive components of a parent structure under mild conditions to produce a closely related analogue that has otherwise inaccessible structures and/or compositions. Refractory materials, such as transition metal borides, are difficult to structurally manipulate at low temperatures because they generally are chemically inert and held together by strong covalent bonds. Here, we report a multistep low-temperature topotactic pathway to bulk-scale Mo2AlB2, which is a metastable phase that has been predicted to be the precursor needed to access a synthetically elusive family of 2-D metal boride (MBene) nanosheets. Room-temperature chemical deintercalation of Al from the stable compound MoAlB (synthesized as a bulk powder at 1400 °C) formed highly strained and destabilized MoAl1-xB, which was size-selectively precipitated to isolate the most reactive submicron grains and then annealed at 600 °C to deintercalate additional Al and crystallize Mo2AlB2. Further heating resulted in topotactic decomposition into bulk-scale Mo2AlB2-AlOx nanolaminates that contain Mo2AlB2 nanosheets with thickness of 1-3 nm interleaved by 1-3 nm of amorphous aluminum oxide. The combination of chemical destabilization, size-selective precipitation, and low-temperature annealing provides a potentially generalizable kinetic pathway to metastable variants of refractory compounds, including bulk Mo2AlB2 and Mo2AlB2-AlOx nanosheet heterostructures, and opens the door to other previously elusive 2-D materials such as 2-D MoB (MBene).

Topochemical Deintercalation of Al from MoAlB: Stepwise Etching Pathway, Layered Intergrowth Structures, and Two-Dimensional MBene.

The synthesis of refractory materials usually relies on high-temperature conditions to drive diffusion-limited solid-state reactions. These reactions result in thermodynamically stable products that are rarely amenable to low-temperature topochemical transformations that postsynthetically modify subtle structural features. Here, we show that topochemical deintercalation of Al from MoAlB single crystals, achieved by room-temperature reaction with NaOH, occurs in a stepwise manner to produce several metastable Mo-Al-B intergrowth phases and a two-dimensional MoB (MBene) monolayer, which is a boride analogue to graphene-like MXene carbides and nitrides. A high-resolution microscopic investigation reveals that stacking faults form in MoAlB as Al is deintercalated and that the stacking fault density increases as more Al is removed. Within nanoscale regions containing high densities of stacking faults, four previously unreported Mo-Al-B (MAB) intergrowth phases were identified, including Mo2AlB2, Mo3Al2B3, Mo4Al3B4, and Mo6Al5B6. One of these deintercalation products, Mo2AlB2, is identified as the likely MAB-phase precursor that is needed to achieve a high-yield synthesis of two-dimensional MoB, a highly targeted two-dimensional MBene. Microscopic evidence of an isolated MoB monolayer is shown, demonstrating the feasibility of using room-temperature metastable-phase engineering and deintercalation to access two-dimensional MBenes.