Layer by layer removal of gold atoms from the (111) surface of gold has been performed using the scanning tunneling microscope. The process is made possible by a chemisorbed self-assembled monolayer (SAM) of dodecanethiol molecules on the surface, which gives rise to a reduced bonding strength between the top two layers of gold atoms. The gold atoms and associated adsorbed molecules are peeled off and displaced laterally by the STM tip, and the size of the modified area (down to $\text{∼10×10\hspace{0.17em}}\mathrm{nm})$ is more or less determined by the scan size.

Many research works have demonstrated that the combination of atomically precise cluster deposition and theoretical calculations is able to address fundamental aspects of size-effects, cluster-support interactions, and reaction mechanisms of cluster materials. Although the wet chemistry method has been widely used to synthesize nanoparticles, the gas-phase synthesis and size-selected strategy was the only method to prepare supported metal clusters with precise numbers of atoms for a long time. However, the low throughput of the physical synthesis method has severely constrained its wider adoption for catalysis applications. In this review, we introduce the latest progress on three types of cluster source which have the most promising potential for scale-up, including sputtering gas aggregation source, pulsed microplasma cluster source, and matrix assembly cluster source. While the sputtering gas aggregation source is leading ahead with a production rate of ∼20 mg·h⁻¹, the pulsed microplasma source has the smallest physical dimensions which makes it possible to compact multiple such devices into a small volume for multiplied production rate. The matrix assembly source has the shortest development history, but already show an impressive deposition rate of ~10 mg·h⁻¹. At the end of the review, the possible routes for further throughput scale-up are envisaged.

Although producing clusters by physical methods offers many benefits, low deposition rates have prevented cluster-beam deposition techniques from being adopted more widely. The influence of the gas aerodynamics inside the condensation chamber of a magnetron cluster-source on the cluster throughput is reported, leading to an improved understanding of the influence of gas aerodynamics on cluster transport. In the first part of this paper, the influence of the carrier gas’s inlet position on the cluster flux is studied. In particular, two inlet configurations were investigated, i.e., from the rear of the chamber and from within the magnetron sputtering source. It was found experimentally that the latter configuration can lead to an increased cluster flux, under the same conditions of gas pressure and power applied to the magnetron. This behavior is explained with the help of simulations. In the second part of this paper, the gas dynamics behavior inside four chamber shapes, namely, two cylindrical shapes with different cross-sectional diameters and two conical shapes with different apex angles, was simulated. The modeling showed that the fraction of clusters successfully leaving the aggregation zone can be increased by up to eight times from the worst to the best performing chamber geometries studied. Finally, the cluster throughput was determined experimentally using a quartz microbalance in two of the four chamber designs. It was found that the cluster flux increased up to one order of magnitude, reaching ∼20 mg/h for a condensation chamber with a smaller cross section and a conical exit.

Bipolar plates are one of the main components of proton exchange membrane fuel cells (PEMFCs). Their functions include distributing reactants, supporting the cell, and conducting heat and electricity. They account for a significant proportion of the fuel cell stack’s weight and volume. The main materials currently used for bipolar plates are graphite and stainless steel. Aluminium has a much lower density than steel and is easier to form than both steel and graphite. Its use, therefore, would allow fuel cells with higher power densities but is hindered due to it being prone to corrosion. This work focused on the development of corrosion-resistant and conductive coatings to address this issue. Carbon coatings with Ti and Cr adhesion layers were deposited on aluminium substrates using closed-field unbalanced magnetron sputtering. These coatings were tested for corrosion properties and performance on the cathode side of a single-cell fuel cell. Coated aluminium samples were also tested for their ability to maintain their corrosion protection after being formed. Coating with a Cr adhesion layer outperformed that with a Ti adhesion layer in both forming and fuel cell tests, demonstrating much lower performance degradation after accelerated stress testing.