Tailored platinum-nickel nanostructures on zirconia developed by metal casting, internal oxidation and dealloying

•Hierarchical structure of pores adjustable by metallurgical means.•Homogenous distribution of nanostructured Pt-Ni onto the surface of highly porous zirconia support.•Initial alloys can be created by a variety of normal metal processing procedures.•Flexible new process for manufacturing catalysts, electrodes and sensors. Noble-metal nanostructures are crucial, highly active materials in applications such as fuel cells, sensors, electrodes and catalysts. The present work shows a new and efficient method for the in-situ synthesis of platinum-nickel nanostructures on porous zirconia. Ni-Zr-Y metallic alloys with defined Zr/Y-ratios and small amounts of platinum are internally oxidized. An interpenetrating network of yttria-stabilized zirconia (YSZ) in pure nickel is formed. Dealloying of the nickel matrix generates a multimodal porous ceramic support structure with platinum-nickel nanostructures on the surface of the zirconia-ceramic with a broad spectrum for tailored functionality, for example in after-treatment of exhaust gases.