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Metal powders with hierarchical nanostructures are always designed andfabricated by dealloying with or without combination of other manufacturingprocesses. However, they are mainly nanoporous metal powder and itsderivations, and their monotonous nanostructures restrict their applications,so metal powders with novel nanostructures should be explored further forvarious applications. Herein, high energy mechanical milling and dealloying canbe combined together for fabricating mass-produced metal powders withcontrollable nanostructures. As an example, a nanograins-attached and ultrathinCu flake powder can be fabricated by high energy mechanical milling of aCu-42wt.%Al powder mixture and subsequent dealloying. The dealloyed Cu powderparticles have ultrathin flaky shapes with numerous Cu grains being attached totheir surfaces, and the microstructure of the as-milled Cu-42wt.%Al powderparticles and the dealloyed Cu particles is studied to elucidate the formationmechanism of the unique morphology of the dealloyed Cu powder.

A nanograins-attached and ultrathin Cu flake powder fabricated by high energy mechanical milling and dealloying