Unveiling Hydrogen-Based Direct Reduction Mechanisms of Multicomponent Oxides via In Situ High-Energy X‑ray...

Co-reduction of multicomponent oxides with hydrogen offers a carbon-neutral approach toward sustainable alloy design. Herein, we use in situ high-energy X-ray diffraction technique to gain insights into multicomponent oxide reduction of two precursor variants: mechanically mixed powders and pre-sintered oxide mixtures, targeting an equiatomic CoFeMnNi alloy. We find distinct reduction pathways and microstructure evolution, depending on initial precursors. Mixed powders are reduced to body-centered-cubic, face-centered-cubic, and MnO phases via halite, spinel, and Mn₃O₄ intermediates, whereas the pre-sintered complex oxide directly transforms into a mixture of metallic and MnO phases. The post-reduction microstructures were also strongly governed by the precursor state: mixed oxides exhibit loosely packed and coarse morphology, whereas the pre-sintered ceramic material showcases two distinct morphologies, either relatively dense metal-rich regions or regions with metallic nanoparticles supported on nanoporous MnO, highlighting the significant role of initial precursors on the final microstructure. Hence, precursor design strategies may offer a single-step route to nanoporous alloys with potential applications in catalysis and energy technologies.