With an aim at developing highly efficient and robust HER catalytic materials that should comprise sufficient available surface with high catalytic activity and have a rational structure with fast electron transfer and reliable steadiness [
36], we construct self-supported monolithic NP Cu/Cu
5Zr electrodes with a hierarchical nanoporous architecture by a facile and scalable dealloying strategy [
46,
47]. Therein, both the nanoporous microstructure and the components are controlled by hereditary effect of precursor Cu
20-xZr
xAl
80 (
, 1, 3, 5, and 20 at%) alloys during the dealloying processes [
46]. Resembling the multiphase-structured Cu
20Al
80 alloy (supplementary Figure S3a), the Cu
20-xZr
xAl
80 (
, 3, and 5 at%) alloys are primarily composed of several-hundred-nanometer-wide
α-Al and CuAl
2 phases with a quasiperiodic distribution, as illustrated by a scanning electron microscope (SEM) backscattered electron image for the Cu
17Zr
3Al
80 alloy (Figure
2(a)) and the corresponding energy-dispersive X-ray spectroscopy (EDS) elemental mappings (Figures
2(b)–
2(d)). X-ray diffraction (XRD) characterization reveals that in addition to
α-Al and CuAl
2 phases, there are intermetallic Cu
5Zr [
48,
49], Al
9.83Zr
0.17 and Al
3Zr clusters that are embedded in Cu-rich and
α-Al phases, respectively, with the incorporation of Zr components (supplementary Figures S3b–d and S4) [
48,
49]. The multiphase structure enables the product of NP Cu/Cu
5Zr with a bimodal nanoporous structure, as that of bare NP Cu (supplementary Figure S5), in a two-step chemical dealloying process: the rapid dissolution of the
α-Al phase embedded with Al
9.83Zr
0.17 and Al
3Zr to form large channels and the selective etching of the less-noble Al component from CuAl
2 alloy to generate small nanopores and expose Cu
5Zr clusters. As shown in a representative SEM image for the NP Cu/Cu
5Zr electrode dealloyed from the precursor Cu
17Zr
3Al
80 alloy (Figure
2(e)), it displays a uniform bimodal nanoporous structure consisting of large channels with ~300 nm in width and small nanopores with the diameter of ~18 nm (supplementary Figure S6). The small nanopore structure is further verified by N
2 adsorption/desorption isotherm (supplementary Figure S7a), which signifies a size distribution with maximum centered at ~18 nm (supplementary Figure S7b). Figure
2(f) shows a typical high-resolution transmission electron microscope (HRTEM) image of Cu/Cu
5Zr ligaments, where high-density intermetallic Cu
5Zr clusters with diameter of ~3-6 nm can be identified by their distinct contrasts and lattices. Atomic resolution high-angle annual-dark-field scanning transmission electron microscope (HAADF-STEM) image viewed along the [111] zone axis illustrates that these Cu
5Zr clusters are exposed and in situ anchored on the NP Cu skeleton with a seamless interfacial structure (Figure
2(g)), enhancing the stability of electroactive Cu
5Zr clusters and their electron transfer with conductive Cu skeleton. The hybrid structure of NP Cu/Cu
5Zr is further verified by the corresponding fast Fourier transform (FFT) patterns (inset of Figure
2(g)) and the XRD patterns (Figure
2(h)) with two sets of diffraction characteristics [
48]. In the XRD patterns, the weak diffraction peaks at
, 43.7, and 45.7 are assigned to the (220), (311), and (222) planes of fcc Cu
5Zr clusters (JCPDS 40-1322) (inset of Figure
2(h)) [
48], apart from the obvious ones attributed to monometallic Cu (JCPDS 04-0836). X-ray photoelectron spectroscopy (XPS) analysis reveals the presence of Zr and Cu with an atomic ratio of 92/5, in addition to a little residual Al according to inductively coupled plasma mass spectroscopy (ICP-MS) and EDS (supplementary Figure S8 and Table S2). The deviation of Zr/Cu ratio from the initial value in the precursor alloy confirms the fact that those Al
9.83Zr
0.17 and Al
3Zr are removed with the dissolution of
α-Al phase. Because of electron donation from Zr to Cu (inset of Figure
2(j)), the Zr 3d XPS spectrum shows the chemical state of Zr
2+ in addition to the Zr
4+ that is due to the oxidation of surface Zr atoms (Figure
2(i)) [
50]. This is in contrast with the observation of solid Cu/Cu
5Zr bulk alloy with negligible Cu
5Zr clusters exposed at the surface (supplementary Figures S9a and b), of which the primary chemical state of Zr
2+ is attributed to the electron transfer from Zr to Cu (supplementary Figure S9c). As a result, Cu exhibits the chemical state of Cu
δ- in addition to Cu
0 and Cu
+ that correspond to the Cu atoms locating at the internal and surface of Cu ligaments, respectively (Figure
2(j) and supplementary Figure S9d) [
34,
51]. Similar dealloying processes also take place in the precursor Cu
20-xZr
xAl
80 alloys with
(Cu
19Zr
1Al
80) or 5 (Cu
15Zr
5Al
80), which gives rise to almost the same bimodal nanoporous structure (supplementary Figures S10a and S11a) except for their distinct Cu/Zr compositions of 97/1 (supplementary Figure S10b) and 80/16 (supplementary Figure S11b), respectively. In contrast, the precursor alloy with
(i.e., Zr
20Al
80) produces NP Zr with a single-modal nanoporous structure during the chemical dealloying (supplementary Figure S12).