Palladium nanoparticles offer an attractive alternative to bulk palladium for catalysis, hydrogen storage and gas sensing applications. Their performance depends strongly on surface structure; therefore, nanoparticle coalescence can play an important role, as it determines the resultant structure of the active sites where reactions (e.g. catalysis) actually take place, i.e. facets, edges, vertices or protrusions. With this in mind, we performed classical molecular dynamics (MD) simulations and magnetron-sputtering inert gas condensation depositions of palladium nanoparticles, supported by high-resolution transmission electron microscopy (HRTEM), to study the mechanisms that govern their coalescence. Surface energy minimisation drove the interactions initially, leading to the formation of an interface/neck, as expected. Intriguingly, at a later stage, atomic rearrangements triggered a crystallisation wave propagating through the amorphous nanoparticles, leading to mono- or polycrystalline fcc structures. In the case of crystalline nanoparticles, almost-epitaxial alignment occurred and the formation of twins and surface protrusions were observed.

To this day, engineering nanoalloys beyond bimetallic compositions has scarcely been within the scope of physical deposition methods due to the complex, non-equilibrium processes they entail. Here, we report a gas-phase synthesis strategy for the growth of multi-metallic nanoparticles: magnetron-sputtering inert-gas condensation from neighboring mono-elemental targets provides the necessary compositional flexibility, while in-depth atomistic computer simulations elucidate the fast kinetics of nucleation and growth that determine the resultant structures. We fabricated consistently trimetallic Au-Pt-Pd nanoparticles, a system of major importance for heterogeneous catalysis applications. Using high-resolution transmission electron microscopy we established their physical and chemical ordering: Au/Pt-rich core@Pd-shell atomic arrangements were identified for particles containing substantial amounts of all elements. Decomposing the growth process into basic steps by molecular dynamics simulations we identified a fundamental difference between Au/Pt and Pd growth dynamics: Au/Pt electronic arrangements favor the formation of dimer nuclei instead of larger-size clusters, thus significantly slowing down their growth rate. Consequently, larger Pd particles formed considerably faster and incorporated small Au and Pt clusters by means of in-flight decoration and coalescence. A broad range of icosahedral, truncated-octahedral, and spheroidal FCC trimetallic nanoparticles were reproduced in simulation, in good agreement with experimental particles. Comparing them with their expected equilibrium structures obtained by Monte Carlo simulations, the particles were identified as metastable, due to out-of-equilibrium growth conditions. We aspire that our in-depth study will constitute a significant advance towards establishing gas-phase aggregation as a standard method for the fabrication of complex nanoparticles by design.

In recent years, due to its inherent flexibility, magnetron-sputtering has been widely used to synthesise bi-metallic nanoparticles (NPs) via subsequent inert-gas cooling and gas-phase condensation of the sputtered atomic vapour. Utilising two separate sputter targets allows for good control over composition. Simultaneously, it involves fast kinetics and non-equilibrium processes, which can trap the nascent NPs into metastable configurations. In this study, we observed such configurations in immiscible, bi-metallic Ag–Cu NPs by scanning transmission electron microscopy (S/TEM) and electron energy-loss spectroscopy (EELS), and noticed a marked difference in the shape of NPs belonging to Ag- and Cu-rich samples. We explained the formation of Janus or Ag@Cu core/shell metastable structures on the grounds of in-flight mixed NP coalescence. We utilised molecular dynamics (MD) and Monte Carlo (MC) computer simulations to demonstrate that such configurations cannot occur as a result of nanoalloy segregation. Instead, sintering at relatively low temperatures can give rise to metastable structures, which eventually can be stabilised by subsequent quenching. Furthermore, we compared the heteroepitaxial diffusivities along various surfaces of both Ag and Cu NPs, and emphasised the differences between the sintering mechanisms of Ag- and Cu-rich NP compositions: small Cu NPs deform as coherent objects on large Ag NPs, whereas small Ag NPs dissolve into large Cu NPs, with their atoms diffusing along specific directions. Taking advantage of this observation, we propose controlled NP coalescence as a method to engineer mixed NPs of a unique, patterned core@partial-shell structure, which we refer to as a “glass-float” (ukidama) structure.

The coalescence of nanoclusters fabricated in the gas phase is a fundamental growth mechanism determining cluster shapes, sizes, compositions, and structures, with resultant effects on practically all of their physical and chemical properties. Furthermore, coalescence can affect properties of larger structures that consist of nanoparticles as their elementary building blocks, such as the fractal dimension of cluster aggregates and the porosity and conductance of thin films. Therefore, it comes as no surprise that a great body of research, both experimental and theoretical, has focused on nanoparticle coalescence over the course of the past few decades. This review attempts to summarize the most important recent results from computational studies on nanoparticle coalescence and draw parallels between theoretical and experimental findings. The approach used here aspires to explain nanoparticle coalescence within the framework of a single intuitive narrative by integrating previous results obtained using various methods by the authors and others. Simultaneously, it is discussed where understanding and controlling (i.e., enhancing or inhibiting) nanoparticle coalescence can have great technological interest.