Atomic
layer deposition (ALD) modification of ultra-high-aspect-ratio
structures (>10000:1) is a powerful platform with applications
in
catalysis, filtration, and energy conversion. However, the deposition
of conformal and tunable ALD coatings at these aspect ratios remains
challenging, resulting in empirical trade-offs between the precursor
utilization and reaction time. Here, we demonstrate tunable control
of the ALD infiltration depth into an aerogel monolith (AM) and develop
a reaction-diffusion model to accurately describe the coating process.
Specifically, we investigate the ALD exposure time and precursor dose
needed to conformally coat a silica AM with pore sizes of ∼20
nm, a monolith thickness of ∼2.5 mm, and aspect ratios exceeding
60000:1. We demonstrate complete infiltration into the AM, which is
quantified by elemental mapping. A reaction-diffusion model is developed,
which accounts for multiple doses and the precursor depletion in the
ALD chamber during an exposure step. The experimentally validated
model enables the prediction and tuning of infiltration depth into
a tortuous, high-aspect-ratio structure such as an AM, allowing for
the synthesis of rationally designed material architectures. Additionally,
the model allows for co-optimization of the total deposition time
and percentage of unreacted precursor, which are important for the
manufacturability and sustainability of ALD processing. Lastly, we
demonstrate that ultrathin ALD Al2O3 coatings
can be used to stabilize silica AMs against structural degradation
under high-temperature annealing conditions (700–800 °C)
by limiting changes in the surface area and monolith volume. This
improved high-temperature stability has implications for numerous
aerogel applications, including catalysis and thermal insulation.