Porous Ti3AlC2 MAX phase enables efficient synthesis of Ti3C2Tx MXene

MXenes, a large family of two-dimensional carbides and/or nitrides, are among the most studied materials worldwide due to their great diversity of structures and compositions. Their unique properties find use in several applications. Typically, they are manufactured by selective wet-chemical etching of layered MAX phase ceramics, which are produced nowadays primarily for MXene synthesis. However, the synthesis of MAX phases has not been changed since the time of their use in structural and high-temperature applications, and it has not been optimized for MXene manufacturing. The main purpose of this study is to develop a porous Ti3AlC2 MAX phase that can be easily ground into individual grains without time-consuming, harsh, and tedious crushing and milling steps. Moreover, we also demonstrate the synthesis of highly porous Ti3AlC2 from an inexpensive titanium sponge instead of a highly pure titanium powder and explain the mechanisms of reaction sintering and formation of porous MAX phase. MXene obtained from this MAX phase, Ti(3)C(2)Tx, shows larger flake size and higher electrical conductivity in thin films, compared to the materials produced from the costly fine titanium powder. The proposed approach may apply to the synthesis of other MAX phases as well.