Elastic Properties of 4-6 nm-thick Glassy Carbon Thin Films

Evolution of Glassy Carbon Derived from Pyrolysis of Furan Resin

Glassy carbon (GC) material derived from pyrolyzed furan resin was modeled by using reactive molecular dynamics (MD) simulations. The MD polymerization simulation protocols to cure the furan resin precursor material are validated via comparison of the predicted density and Young's modulus with experimental values. The MD pyrolysis simulations protocols to pyrolyze the furan resin precursor is validated by comparison of calculated density, Young's modulus, carbon content, sp2 carbon content, the in-plane crystallite size, out-of-plane crystallite stacking height, and interplanar crystallite spacing with experimental results from the literature for furan resin derived GC. The modeling methodology established in this work can provide a powerful tool for the modeling-driven design of next-generation carbon-carbon composite precursor chemistries for thermal protection systems and other high-temperature applications.

Adsorption of Wormlike Chains onto Partially Permeable Membranes

Reversible adsorption of a single stiff wormlike macromolecule to flat membranes with various permeabilities is considered theoretically. It is shown that the adsorbed layer microstructure is significantly different from either a flexible chain or a stiff chain adsorption at a solid surface. Close to the critical point, the adsorbing wormlike chain forms a strongly anisotropic proximal layer near the membrane in addition to a nearly isotropic distal layer. The proximal layer is characterized by the algebraic monomer concentration profile, c(x)∝x-β, due to the self-similar distribution of aligned polymer loops. For a perfectly penetrable membrane, β=1 which is different from β=4/3 obtained for semiflexible chain adsorption at a solid surface. Moreover, we establish that the critical exponent for a partially permeable membrane depends on its properties (porosity w) and propose an asymptotically exact theory (based on the generalized Edwards equation) predicting this dependence, β=β(w). We also develop a scaling theory elucidating, in particular, an intricate competition of loops and tails in both proximal and distal sublayers.

Achieving the theoretical limit of strength in shell-based carbon nanolattices

Recent developments in mechanical metamaterials exemplify a new paradigm shift called mechanomaterials, in which mechanical forces and designed geometries are proactively deployed to program material properties at multiple scales. Here, we designed shell-based micro-/nanolattices with I-WP (Schoen's I-graph-wrapped package) and Neovius minimal surface topologies. Following the designed topologies, polymeric microlattices were fabricated via projection microstereolithography or two-photon lithography, and pyrolytic carbon nanolattices were created through two-photon lithography and subsequent pyrolysis. The shell thickness of created lattice metamaterials varies over three orders of magnitude from a few hundred nanometers to a few hundred micrometers, covering a wider range of relative densities than most plate-based micro-/nanolattices. In situ compression tests showed that the measured modulus and strength of our shell-based micro-/nanolattices with I-WP topology are superior to those of the optimized plate-based lattices with cubic and octet plate unit cells and truss-based lattices. More strikingly, when the density is larger than 0.53 g cm^-3, the strength of shell-based pyrolytic carbon nanolattices with I-WP topology was found to achieve its theoretical limit. In addition, our shell-based carbon nanolattices exhibited an ultrahigh strength of 3.52 GPa, an ultralarge fracture strain of 23%, and an ultrahigh specific strength of 4.42 GPa g^-1 cm³, surpassing all previous micro-/nanolattices at comparable densities. These unprecedented properties can be attributed to the designed topologies inducing relatively uniform strain energy distributions and avoiding stress concentrations as well as the nanoscale feature size. Our study demonstrates a mechanomaterial route to design and synthesize micro-/nanoarchitected materials.

Vitreous Carbon, Geometry and Topology: A Hollistic Approach

Glass-like carbon (GLC) is a complex structure with astonishing properties: isotropic sp2 structure, low density and chemical robustness. Despite the expanded efforts to understand the structure, it remains little known. We review the different models and a physical route (pulsed laser deposition) based on a well controlled annealing of the native 2D/3D amorphous films. The many models all have compromises: neither all bad nor entirely satisfactory. Properties are understood in a single framework given by topological and geometrical properties. To do this, we present the basic tools of topology and geometry at a ground level for 2D surface, graphene being the best candidate to do this. With this in mind, special attention is paid to the hyperbolic geometry giving birth to triply periodic minimal surfaces. Such surfaces are the basic tools to understand the GLC network architecture. Using two theorems (the classification and the uniformisation), most of the GLC properties can be tackled at least at a heuristic level. All the properties presented can be extended to 2D materials. It is hoped that some researchers may find it useful for their experiments.

Plate-nanolattices at the theoretical limit of stiffness and strength

Though beam-based lattices have dominated mechanical metamaterials for the past two decades, low structural efficiency limits their performance to fractions of the Hashin-Shtrikman and Suquet upper bounds, i.e. the theoretical stiffness and strength limits of any isotropic cellular topology, respectively. While plate-based designs are predicted to reach the upper bounds, experimental verification has remained elusive due to significant manufacturing challenges. Here, we present a new class of nanolattices, constructed from closed-cell plate-architectures. Carbon plate-nanolattices are fabricated via two-photon lithography and pyrolysis and shown to reach the Hashin-Shtrikman and Suquet upper bounds, via in situ mechanical compression, nano-computed tomography and micro-Raman spectroscopy. Demonstrating specific strengths surpassing those of bulk diamond and average performance improvements up to 639% over the best beam-nanolattices, this study provides detailed experimental evidence of plate architectures as a superior mechanical metamaterial topology.

Plate-lattices are predicted to reach the upper bounds of strength and stiffness compared to traditional beam-lattices, but they are difficult to manufacture. Here, the authors use two-photon polymerization 3D-printing and pyrolysis to make carbon plate-nanolattices which reach those theoretical bounds, making them up to 639% stronger than beam-nanolattices.

Size Effect on the Strength and Deformation Behavior of Glassy Carbon Nanopillars

Glassy carbon nanolattices can exhibit very high strength-to-weight ratios as a consequence of their small size and the material properties of the constituent material. Such nanolattices can be fabricated by pyrolysis of polymeric microlattices. To further elucidate the influence of the mechanical size effect of the constituent material, compression tests of glassy carbon nanopillars with varying sizes were performed. Depending on the specific initial polymer material and the nanopillar size, varying mechanical properties were observed. Small nanopillars exhibited elastic-plastic deformation before failure initiation. Moreover, for smaller nanopillars higher strength values were observed than for larger ones, which might be related to smaller defects and a lower defect concentration in the material.

Evolution of Glassy Carbon Microstructure: In Situ Transmission Electron Microscopy of the Pyrolysis Process

Glassy carbon is a graphene-rich form of elemental carbon obtained from pyrolysis of polymers, which is composed of three-dimensionally arranged, curved graphene fragments alongside fractions of disordered carbon and voids. Pyrolysis encompasses gradual heating of polymers at ≥ 900 °C under inert atmosphere, followed by cooling to room temperature. Here we report on an experimental method to perform in situ high-resolution transmission electron microscopy (HR-TEM) for the direct visualization of microstructural evolution in a pyrolyzing polymer in the 500-1200 °C temperature range. The results are compared with the existing microstructural models of glassy carbon. Reported experiments are performed at 80 kV acceleration voltage using MEMS-based heating chips as sample substrates to minimize any undesired beam-damage or sample preparation induced transformations. The outcome suggests that the geometry, expansion and atomic arrangement within the resulting graphene fragments constantly change, and that the intermediate structures provide important cues on the evolution of glassy carbon. A complete understanding of the pyrolysis process will allow for a general process tuning specific to the precursor polymer for obtaining glassy carbon with pre-defined properties.

Glassy Carbon: A Promising Material for Micro- and Nanomanufacturing

When certain polymers are heat-treated beyond their degradation temperature in the absence of oxygen, they pass through a semi-solid phase, followed by the loss of heteroatoms and the formation of a solid carbon material composed of a three-dimensional graphenic network, known as glassy (or glass-like) carbon. The thermochemical decomposition of polymers, or generally of any organic material, is defined as pyrolysis. Glassy carbon is used in various large-scale industrial applications and has proven its versatility in miniaturized devices. In this article, micro and nano-scale glassy carbon devices manufactured by (i) pyrolysis of specialized pre-patterned polymers and (ii) direct machining or etching of glassy carbon, with their respective applications, are reviewed. The prospects of the use of glassy carbon in the next-generation devices based on the material's history and development, distinct features compared to other elemental carbon forms, and some large-scale processes that paved the way to the state-of-the-art, are evaluated. Selected support techniques such as the methods used for surface modification, and major characterization tools are briefly discussed. Barring historical aspects, this review mainly covers the advances in glassy carbon device research from the last five years (2013⁻2018). The goal is to provide a common platform to carbon material scientists, micro/nanomanufacturing experts, and microsystem engineers to stimulate glassy carbon device research.

Nanolattices: An Emerging Class of Mechanical Metamaterials

In 1903, Alexander Graham Bell developed a design principle to generate lightweight, mechanically robust lattice structures based on triangular cells; this has since found broad application in lightweight design. Over one hundred years later, the same principle is being used in the fabrication of nanolattice materials, namely lattice structures composed of nanoscale constituents. Taking advantage of the size-dependent properties typical of nanoparticles, nanowires, and thin films, nanolattices redefine the limits of the accessible material-property space throughout different disciplines. Herein, the exceptional mechanical performance of nanolattices, including their ultrahigh strength, damage tolerance, and stiffness, are reviewed, and their potential for multifunctional applications beyond mechanics is examined. The efficient integration of architecture and size-affected properties is key to further develop nanolattices. The introduction of a hierarchical architecture is an effective tool in enhancing mechanical properties, and the eventual goal of nanolattice design may be to replicate the intricate hierarchies and functionalities observed in biological materials. Additive manufacturing and self-assembly techniques enable lattice design at the nanoscale; the scaling-up of nanolattice fabrication is currently the major challenge to their widespread use in technological applications.

Approaching theoretical strength in glassy carbon nanolattices

The strength of lightweight mechanical metamaterials, which aim to exploit material-strengthening size effects by their microscale lattice structure, has been limited by the resolution of three-dimensional lithography technologies and their restriction to mainly polymer resins. Here, we demonstrate that pyrolysis of polymeric microlattices can overcome these limitations and create ultra-strong glassy carbon nanolattices with single struts shorter than 1 μm and diameters as small as 200 nm. They represent the smallest lattice structures yet produced--achieved by an 80% shrinkage of the polymer during pyrolysis--and exhibit material strengths of up to 3 GPa, corresponding approximately to the theoretical strength of glassy carbon. The strength-to-density ratios of the nanolattices are six times higher than those of reported microlattices. With a honeycomb topology, effective strengths of 1.2 GPa at 0.6 g cm(-3) are achieved. Diamond is the only bulk material with a notably higher strength-to-density ratio.

Tailoring the mechanics of ultrathin carbon nanomembranes by molecular design

Freestanding carbon nanomembranes (CNMs) with a thickness between 0.6 and 1.7 nm were prepared from self-assembled monolayers (SAMs) of diverse polyaromatic precursors via low-energy electron-induced cross-linking. The mechanical properties of CNMs were investigated using AFM bulge test, where a pressure difference was applied to the membrane and the resulting deflection was measured by atomic force microscopy. We found a correlation between the rigidity of the precursor molecules and the macroscopic mechanical stiffness of CNMs. While CNMs from rigid and condensed precursors like naphthalene and pyrene thiols prove to exhibit higher Young's moduli of 15-19 GPa, CNMs from nonfused oligophenyls possess lower Young's moduli of ~10 GPa. For CNMs from less densely packed SAMs, the presence of defects and nanopores plays an important role in determining their mechanical properties. The finite element method (FEM) was applied to examine the deformation profiles and simulate the pressure-deflection relationships.

Carbon-silicon Schottky barrier diodes

The simple fabrication of high-performance Schottky barrier diodes between silicon and conductive carbon films (C-Films) is reported. By optimizing the interface, ideality factors as low as n = 1.22 for pyrolytic photoresist films (PPF) have been obtained. These remarkable values, which are not far away from those of commercial products are obtained repeatedly on non-optimized substrates with fully scalable processes.

Room temperature amorphous to nanocrystalline transformation in ultra-thin films under tensile stress: an in situ TEM study

The amorphous to crystalline phase transformation process is typically known to take place at very high temperatures and facilitated by very high compressive stresses. In this study, we demonstrate crystallization of amorphous ultra-thin platinum films at room temperature under tensile stresses. Using a micro-electro-mechanical device, we applied up to 3% uniaxial tensile strain in 3-5 nm thick focused ion beam deposited platinum films supported by another 3-5 nm thick amorphous carbon film. The experiments were performed in situ inside a transmission electron microscope to acquire the bright field and selected area diffraction patterns. The platinum films were observed to crystallize irreversibly from an amorphous phase to face-centered cubic nanocrystals with average grain size of about 10 nm. Measurement of crystal spacing from electron diffraction patterns confirms large tensile residual stress in the platinum specimens. We propose that addition of the externally applied stress provides the activation energy needed to nucleate crystallization, while subsequent grain growth takes place through enhanced atomic and vacancy diffusion as an energetically favorable route towards stress relaxation at the nanoscale.