Ultrasound-assisted fabrication of metal nano-porous shells across polymer beads and their catalytic activity for reduction of 4-nitrophenol

[Display omitted] •New strategy for large scale production of nano-porous metal across 3D templates.•Tuning sonochemical radical formation conditions, morphology and properties of the materials.•Successful deposition of nano-porous and ultra-thin coatings in one-pot synthesis.•New routes towards the design of advanced catalytic surfaces and materials. Metal nano-porous architectures are a novel class of nanomaterials which has been applied in the fields of catalysis, sensing and gas storage because of their high surface-to-volume ratio, high mechanical strength and long-range ordered architectures. A commonly-used synthetic strategies to achieve architectures with high precision and diverse porosity design is the seed-and-growth method. In this work, using a dual-frequency sequential sonication approach, we have demonstrated a sonochemical-assisted one-pot seeding with a successive shell growth synthetic strategy for mesoporous metal deposition via a gold (Au) nanoparticle and poly(styrene) beads system. A uniform coating of gold nanoparticle seeds with dense surface coverage was formed by first employing 300 kHz ultrasound irradiation while the nano-porous shell growth was then performed under 1 MHz ultrasonic frequency. The precise control over the process conditions and parameters allowed for the design of well-defined shell thicknesses and surface roughness and area. The catalytic property of the MNMs was evaluated for the degradation of 4-nitrophenol and a high catalytic activity was achieved for the most porous gold structures, suggesting synergistic effects between the architecture of the nanomaterials and their surface reactivity.