Long-Term Passivation of Strongly Interacting Metals with Single-Layer Graphene

Structural Defects on Graphene Generated by Deposition of CoO: Effect of Electronic Coupling of Graphene

Understanding the interactions in hybrid systems based on graphene and functional oxides is crucial to the applicability of graphene in real devices. Here, we present a study of the structural defects occurring on graphene during the early stages of the growth of CoO, tailored by the electronic coupling between graphene and the substrate in which it is supported: as received pristine graphene on polycrystalline copper (coupled), cleaned in ultra-high vacuum conditions to remove oxygen contamination, and graphene transferred to SiO2/Si substrates (decoupled). The CoO growth was performed at room temperature by thermal evaporation of metallic Co under a molecular oxygen atmosphere, and the early stages of the growth were investigated. On the decoupled G/SiO2/Si samples, with an initial low crystalline quality of graphene, the formation of a CoO wetting layer is observed, identifying the Stranski-Krastanov growth mode. In contrast, on coupled G/Cu samples, the Volmer-Weber growth mechanism is observed. In both sets of samples, the oxidation of graphene is low during the early stages of growth, increasing for the larger coverages. Furthermore, structural defects are developed in the graphene lattice on both substrates during the growth of CoO, which is significantly higher on decoupled G/SiO2/Si samples mainly for higher CoO coverages. When approaching the full coverage on both substrates, the CoO islands coalesce to form a continuous CoO layer with strip-like structures with diameters ranging between 70 and 150 nm.

An overview of contemporary developments and the application of graphene-based materials in anticorrosive coatings

Although graphene and graphene-based materials (GBMs) offer a wide range of possible applications, interest in their use as barrier layers or as reinforcements in coatings for the mitigation of corrosion has grown during the past decade. Because of its unique two-dimensional nanostructure and exceptional physicochemical characteristics, graphene has gotten a lot of attention as an anti-corrosion material. This enthusiasm is largely driven by the requirement to integrate more features, improve anti-corrosion effectiveness, and eventually prolong the service duration of metallic components. As barriers against metal corrosion, graphene nanosheets can be applied singly or in combination to create thin films, layered frameworks, or composites. Concurrently, over the past few years, significant advancements have been made in the establishment of scalable production methods for graphene and materials based on graphene. Since there is currently a wide variety of graphene material with various morphologies and characteristics, it is even more important that the production approach and the intended application be properly matched. This review gathers the most recent data and aims to give the reader a comprehensive overview of the most recent developments in the use of graphene and GBMs in various anti-corrosion strategies. The structure-property correlation and anticorrosion techniques in these systems are given special consideration. The current article offers a critical examination of this topic as well, stressing the areas that require more research.

Enhanced copper anticorrosion from Janus-doped bilayer graphene

The atomic-thick anticorrosion coating for copper (Cu) electrodes is essential for the miniaturisation in the semiconductor industry. Graphene has long been expected to be the ultimate anticorrosion material, however, its real anticorrosion performance is still under great controversy. Specifically, strong electronic couplings can limit the interfacial diffusion of corrosive molecules, whereas they can also promote the surficial galvanic corrosion. Here, we report the enhanced anticorrosion for Cu simply via a bilayer graphene coating, which provides protection for more than 5 years at room temperature and 1000 h at 200 °C. Such excellent anticorrosion is attributed to a nontrivial Janus-doping effect in bilayer graphene, where the heavily doped bottom layer forms a strong interaction with Cu to limit the interfacial diffusion, while the nearly charge neutral top layer behaves inertly to alleviate the galvanic corrosion. Our study will likely expand the application scenarios of Cu under various extreme operating conditions.

Growth Control Strategy of Hydrogen-Containing Nanocrystalline Carbon Films during Plasma-Enhanced Chemical Vapor Deposition based on Molecular Dynamics-Monte Carlo Simulations

Hydrogen-containing nanocrystalline carbon films (n-C:H) with amorphous-nanocrystalline hydrocarbon composite structures exhibit excellent properties in diverse applications. Plasma-enhanced chemical vapor deposition (PECVD) is commonly employed to prepare n-C:H films due to its ability to create an adjustable deposition environment and control film compositions. However, the atomic-scale growth mechanism of n-C:H remains poorly understood, obstructing the design of the appropriate deposition parameters and film compositions. This paper employs a state-of-the-art hybrid molecular dynamics-time-stamped force-biased Monte Carlo model (MD/tfMC) to simulate the plasma-assisted growth of n-C:H. Our results reveal that optimizing the energy of ion bombardments, deposition temperature, and precursor's H:C ratio is crucial for achieving the nucleation and growth of highly ordered n-C:H films. These findings are further validated through experimental observations and density functional theory calculations, which show that hydrogen atoms can promote the formation of nanocrystalline carbon through chemical catalytic processes. Additionally, we find that the crystallinity reaches its optimum when the H/C ratio is equal to 1. These theoretical insights provide an effective strategy for the controlled preparation of hydrogen-containing nanocrystalline carbon films.

Anti-corrosion strategy to improve the stability of perovskite solar cells

In recent years, perovskite solar cells (PSCs) have been considered as one of the most promising photovoltaic technologies due to their solution processing, cost effectiveness, and excellent performance. The highest certified power conversion efficiency (PCE) achieved to date is 25.8%, which is approaching the best PCE of 26.81% achieved for silicon-based cells. However, perovskite materials are susceptible to various aging stressors, such as humidity, oxygen, temperature, and electrical bias, which hinder the industrialization of perovskite photovoltaic technologies. In this review, we discuss the lifetime of PSCs from the perspective of corrosion science. On one hand, benefiting from a series of anti-corrosion strategies (passivation, surface coating, machining etc.) used in corrosion science, the stability of perovskite devices is remarkably enhanced; on the other hand, given that perovskites are soft crystal lattices, which are different from traditional metals, the revealed degradation processes and specific methods to improve device operation stability can be applied to the field of corrosion, which can enrich and expand corrosion science.

Corrosion Resistance of Ultrathin Two-Dimensional Coatings: First-Principles Calculations towards In-Depth Mechanism Understanding and Precise Material Design

In recent years, ultrathin two-dimensional (2D) coatings, e.g., graphene (Gr) and hexagonal boron nitride (h-BN), are intriguing research foci in the field of anticorrosion because their high air stability, excellent impermeability, high optical transparency, and atomistic thickness have endowed them with attractive anticorrosion applications. The microstructure of 2D coatings, coating–substrate interactions, and properties of 2D coatings on substrates in a variety of environmental conditions (e.g., at different temperatures, stresses, and pH values) are the key factors governing the anticorrosion performance of 2D coatings and are among the central topics for all 2D-coating studies. For many conventional experimental measurements (e.g., microscopy and electrochemical methods), there exist challenges to acquire detailed information on the atomistic mechanisms for the involved subnanometer scale corrosion problems. Alternatively, as a precise and efficient quantum-mechanical simulation approach, the first-principles calculation based on density-functional theory (DFT) has become a powerful way to study the thermodynamic and kinetic properties of materials on the atomic scale, as well as to clearly reveal the underlying microscopic mechanisms. In this review, we introduce the anticorrosion performance, existing problems, and optimization ways of Gr and h-BN coatings and summarize important recent DFT results on the critical and complex roles of coating defects and coating–substrate interfaces in governing their corrosion resistance. These DFT progresses have shed much light on the optimization ways towards better anticorrosion 2D coatings and also guided us to make a prospect on the further development directions and promising design schemes for superior anticorrosion ultrathin 2D coatings in the future.

Few-layer graphene on nickel enabled sustainable dropwise condensation

Condensation is critical for a wide range of applications such as electrical power generation, distillation, natural gas processing, dehumidification and water harvest, and thermal management. Compared with "filmwise" mode of condensation (FWC) prevailing in industrial-scale systems, dropwise condensation (DWC) can provide an order of magnitude higher heat transfer rate owing to drastically reduced thermal resistance from the formation of discrete and mobile droplets. In the past, promoting DWC by controlling surface wetting has attracted wide attention, but DWC highly relies on non-wetting surfaces and only lasts days under practical conditions due to the poor reliability of coatings. Here, we developed nanostructured graphene coatings on nickel (Ni) substrates that we can control and enhance the nucleation of water droplets on graphene grain boundaries. Surprisingly, this enables DWC even under normal "wetting" conditions. This is contradictory to the widely accepted DWC mechanism. Moreover, the Ni-graphene surface enables exceptional long-term condensation from days to more than 3 years under practical or even more aggressive testing environments.

Graphene overcoats for ultra-high storage density magnetic media

Hard disk drives (HDDs) are used as secondary storage in digital electronic devices owing to low cost and large data storage capacity. Due to the exponentially increasing amount of data, there is a need to increase areal storage densities beyond ~1 Tb/in². This requires the thickness of carbon overcoats (COCs) to be <2 nm. However, friction, wear, corrosion, and thermal stability are critical concerns below 2 nm, limiting current technology, and restricting COC integration with heat assisted magnetic recording technology (HAMR). Here we show that graphene-based overcoats can overcome all these limitations, and achieve two-fold reduction in friction and provide better corrosion and wear resistance than state-of-the-art COCs, while withstanding HAMR conditions. Thus, we expect that graphene overcoats may enable the development of 4-10 Tb/in² areal density HDDs when employing suitable recording technologies, such as HAMR and HAMR+bit patterned media.

Graphene Coating Obtained in a Cold-Wall CVD Process on the Co-Cr Alloy (L-605) for Medical Applications

Graphene coating on the cobalt-chromium alloy was optimized and successfully carried out by a cold-wall chemical vapor deposition (CW-CVD) method. A uniform layer of graphene for a large area of the Co-Cr alloy (discs of 10 mm diameter) was confirmed by Raman mapping coated area and analyzing specific G and 2D bands; in particular, the intensity ratio and the number of layers were calculated. The effect of the CW-CVD process on the microstructure and the morphology of the Co-Cr surface was investigated by scanning X-ray photoelectron microscope (SPEM), atomic force microscopy (AFM), scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS). Nanoindentation and scratch tests were performed to determine mechanical properties of Co-Cr disks. The results of microbiological tests indicate that the studied Co-Cr alloys covered with a graphene layer did not show a pro-coagulant effect. The obtained results confirm the possibility of using the developed coating method in medical applications, in particular in the field of cardiovascular diseases.

Polycrystalline Few-Layer Graphene as a Durable Anticorrosion Film for Copper

Corrosion of metals in atmospheric environments is a worldwide problem in industry and daily life. Traditional anticorrosion methods including sacrificial anodes or protective coatings have performance limitations. Here, we report atomically thin, polycrystalline few-layer graphene (FLG) grown by chemical vapor deposition as a long-term protective coating film for copper (Cu). A six-year old, FLG-protected Cu is visually shiny and detailed material characterizations capture no sign of oxidation. The success of the durable anticorrosion film depends on the misalignment of grain boundaries between adjacent graphene layers. Theoretical calculations further found that corrosive molecules always encounter extremely high energy barrier when diffusing through the FLG layers. Therefore, the FLG is able to prevent the corrosive molecules from reaching the underlying Cu surface. This work highlights the interesting structures of polycrystalline FLG and sheds insight into the atomically thin coatings for various applications.

Graphene Layer Morphology as an Indicator of the Metal Alloy Formation at the Interface

The intercalation of different species in graphene-metal interfaces is widely used to stabilize the artificial phases of different materials, which in some cases leads to the formation of the surface alloys between atoms of the guest metal and the substrate. Here, the interfaces of graphene with Ru(0001) and Ir(111) were modified using intercalation of a thin Mn layer and investigated by means of scanning tunneling microscopy (STM) accompanied by density functional theory (DFT) calculations. It is found that Mn forms a pseudomorphic layer on Ru(0001) under a strongly buckled graphene layer. In the case of Mn intercalation in graphene/Ir(111), a buried thin layer of MnIr alloy is formed beneath the first Ir layer under a flat graphene layer. This unexpected observation is explained on the basis of phase diagram pictures for the Mn-Ru and Mn-Ir systems as well as via comparison of calculated total energies for the respective interfaces.

Effects of thermal treatments on the hydrophobicity and anticorrosion properties of as-grown graphene coatings

Graphene grown on metal substrates has been reported to provide efficient and robust hydrophobicity during water vapor condensation on metal surfaces. However, due to the intrinsic negative coefficient of thermal expansion (CTE) of graphene, the potential thermal stress in real application environments can cause CTE mismatch and then damage the protective graphene coatings, leading to loss of surface hydrophobicity and anticorrosion properties. In this study, the effect of thermal treatments on anticorrosion properties and subsequent hydrophobicity of the graphene surface has been investigated. The as-grown graphene on nickel (Ni–Gr) is explored in terms of survival under severe thermal cycling (up to 14.62 °C s⁻¹) and effectively maintains its surface properties. As a comparison, the as-grown graphene on copper (Cu–Gr) easily peeled off from the metal surface due to the thermal stress and intercalation of oxides. The thermal treatment at 200 °C under ambient atmosphere can elevate the corrosion rate 2.2 times and 29 times on the Ni–Gr and Cu–Gr surfaces compared to situations without thermal treatments, respectively. This study shows that the Ni–Gr surface is significantly more robust than the Cu–Gr surface as a sustainable hydrophobic surface in a complicated thermal environment.

Thermal treatments can significantly affect the anticorrosion properties and the subsequent surface hydrophobicity of graphene-metal systems with varied interfacial bonds.

Intercalation of Mn in graphene/Cu(111) interface: insights to the electronic and magnetic properties from theory

The effect of Mn intercalation on the atomic, electronic and magnetic structure of the graphene/Cu(111) interface is studied using state-of-the-art density functional theory calculations. Different structural models of the graphene-Mn-Cu(111) interface are investigated. While a Mn monolayer placed between graphene and Cu(111) (an unfavorable configuration) yields massive rearrangement of the graphene-derived [Formula: see text] bands in the vicinity of the Fermi level, the possible formation of a [Formula: see text]Mn alloy at the interface (a favorable configuration) preserves the linear dispersion for these bands. The deep analysis of the electronic states around the Dirac point for the graphene/[Formula: see text]Mn/Cu(111) system allows to discriminate between contributions from three carbon sublattices of a graphene layer in this system and to explain the bands' as well as spins' topology of the electronic states around the Fermi level.

Oxygen intercalation in PVD graphene grown on copper substrates: A decoupling approach

We investigate the intercalation process of oxygen in-between a PVD-grown graphene layer and different copper substrates as a methodology for reducing the substrate-layer interaction. This growth method leads to an extended defect-free graphene layer that strongly couples with the substrate. We have found, by means of X-ray photoelectron spectroscopy, that after oxygen exposure at different temperatures, ranging from 280 °C to 550 °C, oxygen intercalates at the interface of graphene grown on Cu foil at an optimal temperature of 500 °C. The low energy electron diffraction technique confirms the adsorption of an atomic oxygen adlayer on top of the Cu surface and below graphene after oxygen exposure at elevated temperature, but no oxidation of the substrate is induced. The emergence of the 2D Raman peak, quenched by the large interaction with the substrate, reveals that the intercalation process induces a structural undoing. As suggested by atomic force microscopy, the oxygen intercalation does not change significantly the surface morphology. Moreover, theoretical simulations provide further insights into the electronic and structural undoing process. This protocol opens the door to an efficient methodology to weaken the graphene-substrate interaction for a more efficient transfer to arbitrary surfaces.

Crystal Orientation Dependent Oxidation Modes at the Buried Graphene-Cu Interface

We combine spatially resolved scanning photoelectron spectroscopy with confocal Raman and optical microscopy to reveal how the oxidation of the buried graphene-Cu interface relates to the Cu crystallographic orientation. We analyze over 100 different graphene covered Cu (high and low index) orientations exposed to air for 2 years. Four general oxidation modes are observed that can be mapped as regions onto the polar plot of Cu surface orientations. These modes are (1) complete, (2) irregular, (3) inhibited, and (4) enhanced wrinkle interface oxidation. We present a comprehensive characterization of these modes, consider the underlying mechanisms, compare air and water mediated oxidation, and discuss this in the context of the diverse prior literature in this area. This understanding incorporates effects from across the wide parameter space of 2D material interface engineering, relevant to key challenges in their emerging applications, ranging from scalable transfer to electronic contacts, encapsulation, and corrosion protection.

Epitaxial graphene/Ge interfaces: a minireview

The recent discovery of the ability to perform direct epitaxial growth of graphene layers on semiconductor Ge surfaces led to a huge interest in this topic. One of the reasons for this interest is the chance to overcome several present-day drawbacks on the method of graphene integration in modern semiconductor technology. The other one is connected with the fundamental studies of the new graphene-semiconductor interfaces that might help with the deeper understanding of mechanisms, which governs graphene growth on different substrates as well as shedding light on the interaction of graphene with these substrates, whose range is now spread from metals to insulators. The present minireview gives a timely overview of the state-of-the-art field of studies of the graphene-Ge epitaxial interfaces and draws some conclusions in this research area.

Investigation of the Oxidation Behavior of Graphene/Ge(001) Versus Graphene/Ge(110) Systems

The oxidation behavior of Ge(001) and Ge(110) surfaces underneath the chemical vapor deposition (CVD)-grown graphene films has been investigated experimentally and interpreted on the basis of ab initio calculations. Freshly grown samples were exposed to air for more than 7 months and periodically monitored by X-ray photoelectron spectroscopy, scanning electron microscopy, and Raman spectroscopy. The oxidation of Ge(110) started with incubation time of several days, during which the oxidation rate was supposedly exponential. After an ultrathin oxide grew, the oxidation continued with a slow but constant rate. No incubation was detected for Ge(001). The oxide thickness was initially proportional to the square root of time. After 2 weeks, the rate saturated at a value fivefold higher than that for Ge(110). We argue that after the initial phase, the oxidation is limited by the diffusion of oxidizing species through atomic-size openings at graphene domain boundaries and is influenced by the areal density and by the structural quality of the boundaries, whereby the latter determines the initial behavior. Prolonged exposure affected the surface topography and reduced the strain in graphene. In the last step, both the air-exposed samples were annealed in vacuum at 850 °C. This removed oxygen from the substrate and restored the samples to their initial state. These findings might constitute an important step toward further optimization of graphene grown on Ge.

Avoiding oxidation with coating: graphene protected magnesium surfaces

Magnesium is a promising material for automotive technology. Avoiding its spontaneous oxidation is, however, mandatory for a feasible industrial application of this metal. We perform computer simulations to demonstrate that a protective graphene layer can successfully avoid the oxidation of a magnesium material. This feature remains true even when the graphene layer has several simple defects, such as vacancies and Stone-Wales transformations. In fact, the defects actually increase the strength of the graphene/metal interaction, further enhancing the protective properties. These results are rationalized in terms of the low Mg cohesive energy, which allows the system to quickly reconstruct and adapt.

A Peeling Approach for Integrated Manufacturing of Large Monolayer h-BN Crystals

Hexagonal boron nitride (h-BN) is the only known material aside from graphite with a structure composed of simple, stable, noncorrugated atomically thin layers. While historically used as a lubricant in powder form, h-BN layers have become particularly attractive as an ultimately thin insulator, barrier, or encapsulant. Practically all emerging electronic and photonic device concepts currently rely on h-BN exfoliated from small bulk crystallites, which limits device dimensions and process scalability. We here focus on a systematic understanding of Pt-catalyzed h-BN crystal formation, in order to address this integration challenge for monolayer h-BN via an integrated chemical vapor deposition (CVD) process that enables h-BN crystal domain sizes exceeding 0.5 mm and a merged, continuous layer in a growth time of less than 45 min. The process makes use of commercial, reusable Pt foils and allows a delamination process for easy and clean h-BN layer transfer. We demonstrate sequential pick-up for the assembly of graphene/h-BN heterostructures with atomic layer precision, while minimizing interfacial contamination. The approach can be readily combined with other layered materials and enables the integration of CVD h-BN into high-quality, reliable 2D material device layer stacks.

Carbon Nanotubes and Related Nanomaterials: Critical Advances and Challenges for Synthesis toward Mainstream Commercial Applications

Advances in the synthesis and scalable manufacturing of single-walled carbon nanotubes (SWCNTs) remain critical to realizing many important commercial applications. Here we review recent breakthroughs in the synthesis of SWCNTs and highlight key ongoing research areas and challenges. A few key applications that capitalize on the properties of SWCNTs are also reviewed with respect to the recent synthesis breakthroughs and ways in which synthesis science can enable advances in these applications. While the primary focus of this review is on the science framework of SWCNT growth, we draw connections to mechanisms underlying the synthesis of other 1D and 2D materials such as boron nitride nanotubes and graphene.

Role of the Cu substrate in the growth of ultra-flat crack-free highly-crystalline single-layer graphene

Producing ultra-flat crack-free single-layer high-quality graphene over large areas has remained the key challenge to fully exploit graphene's potential into next-generation technological applications. In this regard, we show that epitaxial Cu(111) film represents the most promising catalyst for the chemical vapor deposition (CVD) of graphene with superior planarity and physical integrity. We first compare the most widely used Cu catalysts (foils, polycrystalline films and epitaxial films) in order to benchmark the roughness of the Cu surface which serves as a template for graphene growth. We then discuss the correlation between the formation of cracks and wrinkles in as-grown graphene and the surface morphology of these various Cu catalysts. In particular, Cu grain boundary grooves, inherently present in polycrystalline substrates, are found to contribute to the formation of cracks. Finally, we focused on tuning the CVD protocol in order to successfully grow highly crystalline graphene made of millimeter-size domains on every type of catalyst while mitigating Cu surface roughening. Putting into context the challenges and opportunities associated with the most widely used Cu catalysts provides valuable guidelines for high-throughput manufacturing of graphene suitable for emerging industrial applications.

Polymerization driven monomer passage through monolayer chemical vapour deposition graphene

Mass transport through graphene is receiving increasing attention due to the potential for molecular sieving. Experimental studies are mostly limited to the translocation of protons, ions, and water molecules, and results for larger molecules through graphene are rare. Here, we perform controlled radical polymerization with surface-anchored self-assembled initiator monolayer in a monomer solution with single-layer graphene separating the initiator from the monomer. We demonstrate that neutral monomers are able to pass through the graphene (via native defects) and increase the graphene defects ratio (Raman I_D/I_G) from ca. 0.09 to 0.22. The translocations of anionic and cationic monomers through graphene are significantly slower due to chemical interactions of monomers with the graphene defects. Interestingly, if micropatterned initiator-monolayers are used, the translocations of anionic monomers apparently cut the graphene sheet into congruent microscopic structures. The varied interactions between monomers and graphene defects are further investigated by quantum molecular dynamics simulations.

Enhancing Graphene Protective Coatings by Hydrogen-Induced Chemical Bond Formation

Increased interactions at the graphene-metal interface are here demonstrated to yield an effective prevention of intercalation of foreign species below the graphene cover. Hereby, an engineering pathway for increasing the usability of graphene as a metal coating is demonstrated. Graphene on Ir(111) (Gr/Ir(111)) is used as a model system, as it has previously been well-established that an increased interaction and formation of chemical bonds at the graphene-Ir interface can be induced by hydrogen functionalization of the graphene from its top side. With X-ray photoelectron spectroscopy, it is shown that hydrogen-induced increased interactions at the Gr/Ir(111) interface effectively prevents intercalation of CO in the millibar range. The scheme leads to protection against at least 10 times higher pressure and 70 times higher fluences of CO, compared to the protection offered by pristine Gr/Ir(111).

Nondestructive Thickness Mapping of Wafer-Scale Hexagonal Boron Nitride Down to a Monolayer

The availability of an accurate, nondestructive method for measuring thickness and continuity of two-dimensional (2D) materials with monolayer sensitivity over large areas is of pivotal importance for the development of new applications based on these materials. While simple optical contrast methods and electrical measurements are sufficient for the case of metallic and semiconducting 2D materials, the low optical contrast and high electrical resistivity of wide band gap dielectric 2D materials such as hexagonal boron nitride (hBN) hamper their characterization. In this work, we demonstrate a nondestructive method to quantitatively map the thickness and continuity of hBN monolayers and bilayers over large areas. The proposed method is based on acquisition and subsequent fitting of ellipsometry spectra of hBN on Si/SiO₂ substrates. Once a proper optical model is developed, it becomes possible to identify and map the commonly observed polymer residuals from the transfer process and obtain submonolayer thickness sensitivity for the hBN film. With some assumptions on the optical functions of hBN, the thickness of an as-transferred hBN monolayer on SiO₂ is measured as 4.1 Å ± 0.1 Å, whereas the thickness of an air-annealed hBN monolayer on SiO₂ is measured as 2.5 Å ± 0.1 Å. We argue that the difference in the two measured values is due to the presence of a water layer trapped between the SiO₂ surface and the hBN layer in the latter case. The procedure can be fully automated to wafer scale and extended to other 2D materials transferred onto any polished substrate, as long as their optical functions are approximately known.

Revisiting graphene-polymer nanocomposite for enhancing anticorrosion performance: a new insight into interface chemistry and diffusion model

Graphene is impermeable to all molecules and has high chemical stability, which makes it an excellent anticorrosion coating for metals. However, current studies have indicated that galvanic coupling between graphene and a metal actually accelerates corrosion at the interface. Due to the insulating nature of polymers, graphene-polymer composite coatings with a strong interaction between the filler and the polymer matrix are an alternative means of addressing this issue. Nevertheless, such coatings require well-dispersed graphene flakes to lengthen the diffusion paths of gases or liquids, while preventing the formation of a conducting network from graphene to the metal. The difficulty in preparing such coatings was mainly due to problems with the control of the assembled phase during interfacial reactions. Herein, the interactions between the filler and the polymer were found to be a key factor governing anticorrosion performance, which has scarcely been previously reported. The advantage of graphene as a filler in anticorrosion coatings lies in its dispersibility and miscibility with both the casting solvent and the polymer. Electrochemically exfoliated graphene (EC-graphene) with appropriate surface functionalities that allow high miscibility with waterborne polyurethane (PU) and hydrophobic epoxy has been found to be an ideal filler that outperforms other graphene materials such as graphene oxide (GO) and reduced graphene oxide (rGO). Furthermore, a bilayer coating with EC-graphene additives for PU over epoxy has been found to reduce the corrosion rate (CR) to 1.81 × 10-5 mm per year. With a graphene loading of less than 1%, this represents the lowest CR ever achieved for copper and steel substrates and a diffusion coefficient that is lower by a factor of nearly 2.2 than that of the pristine polymer. Furthermore, we have shown that by controlling the amount of graphene loaded in the polymer galvanic corrosion favored by the formation of an interconnected graphene percolation network can successfully be limited. The present study, together with a facile and eco-friendly method of nanocomposite synthesis, may pave the way toward practical applications in the development of graphene-based anticorrosion coatings.

Insulator-to-Metallic Spin-Filtering in 2D-Magnetic Tunnel Junctions Based on Hexagonal Boron Nitride

We report on the integration of atomically thin 2D insulating hexagonal boron nitride (h-BN) tunnel barriers into magnetic tunnel junctions (2D-MTJs) by fabricating two illustrative systems (Co/h-BN/Co and Co/h-BN/Fe) and by discussing h-BN potential for metallic spin filtering. The h-BN is directly grown by chemical vapor deposition on prepatterned Co and Fe stripes. Spin-transport measurements reveal tunnel magneto-resistances in these h-BN-based MTJs as high as 12% for Co/h-BN/h-BN/Co and 50% for Co/h-BN/Fe. We analyze the spin polarizations of h-BN/Co and h-BN/Fe interfaces extracted from experimental spin signals in light of spin filtering at hybrid chemisorbed/physisorbed h-BN, with support of ab initio calculations. These experiments illustrate the strong potential of h-BN for MTJs and are expected to ignite further investigations of 2D materials for large signal spin devices.

High-resistivity metal-oxide films through an interlayer of graphene grown directly on copper electrodes

Functional oxides are important materials for multiple applications in flexible and transparent electronics. Electrically contacting these oxides to form active channels is often challenging as they suffer significant alteration or instabilities when interfaced with metal electrodes. Here, we demonstrate a new scheme to electrically contact thin films of semiconducting zinc tin oxide (ZnSnO) that employs pre-patterned copper electrodes encapsulated by chemical-vapour-deposited graphene. Measurement of over more than 100 channels with varying geometry and nature of contact shows that the bulk resistivity of the ZnSnO channels with graphene/Cu composite is at least two orders of magnitude larger than the same films deposited directly on aluminium (Al) contacts. Moreover, the ZnSnO channels with Cu/graphene contacts showed nearly ohmic transport, in contrast to space-charge-limited conduction observed for other contacting schemes. Our results outline a new application of graphene in a step towards the development of alternative contacting strategies for oxide electronics.

Low temperature growth of fully covered single-layer graphene using a CoCu catalyst

A bimetallic CoCu alloy thin-film catalyst is developed that enables the growth of uniform, high-quality graphene at 750 °C in 3 min by chemical vapour deposition. The growth outcome is found to vary significantly as the Cu concentration is varied, with ∼1 at% Cu added to Co yielding complete coverage single-layer graphene growth for the conditions used. The suppression of multilayer formation is attributable to Cu decoration of high reactivity sites on the Co surface which otherwise serve as preferential nucleation sites for multilayer graphene. X-ray photoemission spectroscopy shows that Co and Cu form an alloy at high temperatures, which has a drastically lower carbon solubility, as determined by using the calculated Co-Cu-C ternary phase diagram. Raman spectroscopy confirms the high quality (I_D/I_G < 0.05) and spatial uniformity of the single-layer graphene. The rational design of a bimetallic catalyst highlights the potential of catalyst alloying for producing two-dimensional materials with tailored properties.

From Growth Surface to Device Interface: Preserving Metallic Fe under Monolayer Hexagonal Boron Nitride

We investigate the interfacial chemistry between Fe catalyst foils and monolayer hexagonal boron nitride (h-BN) following chemical vapor deposition and during subsequent atmospheric exposure, using scanning electron microscopy, X-ray photoemission spectroscopy, and scanning photoelectron microscopy. We show that regions of the Fe surface covered by h-BN remain in a metallic state during exposure to moist air for ∼40 h at room temperature. This protection is attributed to the strong interfacial interaction between h-BN and Fe, which prevents the rapid intercalation of oxidizing species. Local Fe oxidation is observed on bare Fe regions and close to defects in the h-BN film (e.g., domain boundaries, wrinkles, and edges), which over the longer-term provide pathways for slow bulk oxidation of Fe. We further confirm that the interface between h-BN and metallic Fe can be recovered by vacuum annealing at ∼600 °C, although this is accompanied by the creation of defects within the h-BN film. We discuss the importance of these findings in the context of integrated manufacturing and transfer-free device integration of h-BN, particularly for technologically important applications where h-BN has potential as a tunnel barrier such as magnetic tunnel junctions.

Assessment and control of the impermeability of graphene for atomically thin membranes and barriers

Two-dimensional materials such as graphene offer fundamentally transformative opportunities in membrane separations and as impermeable barriers, but the lack of facile methods to assess and control its 'impermeability' critically limits progress. Here we show that a simple etch of the growth catalyst (Cu) through defects in monolayer graphene synthesized by chemical vapor deposition (CVD) can be used to effectively assess graphene quality for membrane/barrier applications. Using feedback from the method to tune synthesis, we realize graphene with nearly no nanometer-scale defects as assessed by diffusion measurements, in contrast to commercially available graphene that is largely optimized for electronic applications. Interestingly, we observe clear evidence of leakage through larger defects associated with wrinkles in graphene, which are selectively sealed to realize centimeter-scale atomically thin barriers exhibiting <2% mass transport compared to the graphene support. Our work provides a facile method to assess and control the 'impermeability' of graphene and shows that future work should be directed towards the control of leakage associated with wrinkles.

Defects Mediated Corrosion in Graphene Coating Layer

Mixed results were reported on the anticorrosion of graphene-coated metal surfaces-while graphene serves as an effective short-term barrier against corrosion and oxidation due to its low permeability to gases, the galvanic cell between graphene and the metal substrate facilitates extensive corrosion in the long run. Defects in the graphene layer provide pathways for the permeation of oxidizing species. We study the role of defects in graphene in the anticorrosion using first-principles theoretical modeling. Experiments in the highly reactive environment indicate that the oxidized products primarily distribute along the grain boundaries of graphene. We analyze the thermodynamics of the absorption of S and O on the grain boundaries of graphene on the basis of density functional theory. The insertion of S and O at the vacancy sites is energetically favorable. The interstitial impurities facilitate structural transformation of graphene and significantly decrease the mechanical strength of the graphene layer. Furthermore, the presence of the interstitial S and O reduces the chemical stability of graphene by enhancing the formation of vacancies and promoting dispersive growth of corrosive reactants along the grain boundaries.

Effects of surface oxidation of Cu substrates on the growth kinetics of graphene by chemical vapor deposition

Although the success of graphene research has opened up a new route for wearable electronic and optoelectronic devices, producing graphene with controllable quality and cost-effective growth on a large scale remains challenging due to the lack of understanding about its growth kinetics. Domain boundaries interrupt lattice continuity of graphene; therefore, lowering the nucleation density at the initial stage of graphene growth in the chemical vapor deposition (CVD) process is beneficial for improving the quality of graphene for applications. Herein, we show that by forming an oxide passivation layer on Cu substrates before CVD graphene growth, graphene nucleation density can be effectively decreased. The nucleation mechanism in the presence of an oxide passivation layer is of interest. The analysis of graphene growth kinetics suggests that the thickness of the boundary layer for mass transfer on the substrate surface plays an important role in controlling the reduction rate of the oxide passivation layer. A thick boundary layer created under slow gas flow causes slow reduction of the oxide passivation layer, making finite sites for graphene nucleation. The domain density in a graphene layer is therefore significantly reduced. Graphene sheets of various domain densities (ranging from 10⁴ to 1 mm^-2) can be fabricated by suitably choosing the growth parameters. The graphene sheet with a lower density of domain boundaries exhibits better electrical conductivities.

Influence of Graphene Reduction and Polymer Cross-Linking on Improving the Interfacial Properties of Multilayer Thin Films

Graphene is a versatile composite reinforcement candidate due to its strong mechanical, tunable electrical and optical properties, and chemical stability. However, one drawback is the weak interfacial bonding, which results in weak adhesion to substrates. This could be overcome by adding polymer layers to have stronger adherence to the substrate and between graphene sheets. These multilayer thin films were found to have lower resistance to lateral scratch forces when compared to other reinforcements such as polymer/clay nanocomposites. Two additional processing steps are suggested to improve the scratch resistance of these films: graphene reduction and polymer cross-linking. Graphene/polymer nanocomposites consisting of polyvinylamine (PVAm) and graphene oxide (GO) were fabricated using the layer-by-layer assembly (LbL) technique. The reduced elastic modulus and hardness of PVAm/GO films were measured using nanoindentation. Reducing GO enhances mechanical properties by 60-70% while polymer cross-linking maintains this enhancement. Both graphene reduction and polymer cross-linking show significant improvement to scratch resistance. Particularly, polymer cross-linking leads to films with higher elastic recovery, 50% lower adhesive and plowing friction coefficient, 140 and 50% higher adhesive and shear strength values, respectively, and lower material pileup and scratch width/depth.

Real-time oxide evolution of copper protected by graphene and boron nitride barriers

Applying protective or barrier layers to isolate a target item from the environment is a common approach to prevent or delay its degradation. The impermeability of two-dimensional materials such as graphene and hexagonal boron nitride (hBN) has generated a great deal of interest in corrosion and material science. Owing to their different electronic properties (graphene is a semimetal, whereas hBN is a wide-bandgap insulator), their protection behaviour is distinctly different. Here we investigate the performance of graphene and hBN as barrier coatings applied on copper substrates through a real-time study in two different oxidative conditions. Our findings show that the evolution of the copper oxidation is remarkably different for the two coating materials.

Surface chemistry and catalysis confined under two-dimensional materials

Interfaces between 2D material overlayers and solid surfaces provide confined spaces for chemical processes, which have stimulated new chemistry under a 2D cover.

Atomically Thin Hexagonal Boron Nitride Nanofilm for Cu Protection: The Importance of Film Perfection

Outstanding protection of Cu by high-quality boron nitride nanofilm (BNNF) 1-2 atomic layers thick in salt water is observed, while defective BNNF accelerates the reaction of Cu toward water. The chemical stability, insulating nature, and impermeability of ions through the BN hexagons render BNNF a great choice for atomic-scale protection.

Catalyst Interface Engineering for Improved 2D Film Lift-Off and Transfer

The mechanisms by which chemical vapor deposited (CVD) graphene and hexagonal boron nitride (h-BN) films can be released from a growth catalyst, such as widely used copper (Cu) foil, are systematically explored as a basis for an improved lift-off transfer. We show how intercalation processes allow the local Cu oxidation at the interface followed by selective oxide dissolution, which gently releases the 2D material (2DM) film. Interfacial composition change and selective dissolution can thereby be achieved in a single step or split into two individual process steps. We demonstrate that this method is not only highly versatile but also yields graphene and h-BN films of high quality regarding surface contamination, layer coherence, defects, and electronic properties, without requiring additional post-transfer annealing. We highlight how such transfers rely on targeted corrosion at the catalyst interface and discuss this in context of the wider CVD growth and 2DM transfer literature, thereby fostering an improved general understanding of widely used transfer processes, which is essential to numerous other applications.

In Situ Graphene Growth Dynamics on Polycrystalline Catalyst Foils

The dynamics of graphene growth on polycrystalline Pt foils during chemical vapor deposition (CVD) are investigated using in situ scanning electron microscopy and complementary structural characterization of the catalyst with electron backscatter diffraction. A general growth model is outlined that considers precursor dissociation, mass transport, and attachment to the edge of a growing domain. We thereby analyze graphene growth dynamics at different length scales and reveal that the rate-limiting step varies throughout the process and across different regions of the catalyst surface, including different facets of an individual graphene domain. The facets that define the domain shapes lie normal to slow growth directions, which are determined by the interfacial mobility when attachment to domain edges is rate-limiting, as well as anisotropy in surface diffusion as diffusion becomes rate-limiting. Our observations and analysis thus reveal that the structure of CVD graphene films is intimately linked to that of the underlying polycrystalline catalyst, with both interfacial mobility and diffusional anisotropy depending on the presence of step edges and grain boundaries. The growth model developed serves as a general framework for understanding and optimizing the growth of 2D materials on polycrystalline catalysts.

In Situ Observations of Phase Transitions in Metastable Nickel (Carbide)/Carbon Nanocomposites

Nanocomposite thin films comprised of metastable metal carbides in a carbon matrix have a wide variety of applications ranging from hard coatings to magnetics and energy storage and conversion. While their deposition using nonequilibrium techniques is established, the understanding of the dynamic evolution of such metastable nanocomposites under thermal equilibrium conditions at elevated temperatures during processing and during device operation remains limited. Here, we investigate sputter-deposited nanocomposites of metastable nickel carbide (Ni₃C) nanocrystals in an amorphous carbon (a-C) matrix during thermal postdeposition processing via complementary in situ X-ray diffractometry, in situ Raman spectroscopy, and in situ X-ray photoelectron spectroscopy. At low annealing temperatures (300 °C) we observe isothermal Ni₃C decomposition into face-centered-cubic Ni and amorphous carbon, however, without changes to the initial finely structured nanocomposite morphology. Only for higher temperatures (400-800 °C) Ni-catalyzed isothermal graphitization of the amorphous carbon matrix sets in, which we link to bulk-diffusion-mediated phase separation of the nanocomposite into coarser Ni and graphite grains. Upon natural cooling, only minimal precipitation of additional carbon from the Ni is observed, showing that even for highly carbon saturated systems precipitation upon cooling can be kinetically quenched. Our findings demonstrate that phase transformations of the filler and morphology modifications of the nanocomposite can be decoupled, which is advantageous from a manufacturing perspective. Our in situ study also identifies the high carbon content of the Ni filler crystallites at all stages of processing as the key hallmark feature of such metal-carbon nanocomposites that governs their entire thermal evolution. In a wider context, we also discuss our findings with regard to the much debated potential role of metastable Ni₃C as a catalyst phase in graphene and carbon nanotube growth.

Visualising the strain distribution in suspended two-dimensional materials under local deformation

We demonstrate the use of combined simultaneous atomic force microscopy (AFM) and laterally resolved Raman spectroscopy to study the strain distribution around highly localised deformations in suspended two-dimensional materials. Using the AFM tip as a nanoindentation probe, we induce localised strain in suspended few-layer graphene, which we adopt as a two-dimensional membrane model system. Concurrently, we visualise the strain distribution under and around the AFM tip in situ using hyperspectral Raman mapping via the strain-dependent frequency shifts of the few-layer graphene's G and 2D Raman bands. Thereby we show how the contact of the nm-sized scanning probe tip results in a two-dimensional strain field with μm dimensions in the suspended membrane. Our combined AFM/Raman approach thus adds to the critically required instrumental toolbox towards nanoscale strain engineering of two-dimensional materials.

Graphene Membranes for Atmospheric Pressure Photoelectron Spectroscopy

Atmospheric pressure X-ray photoelectron spectroscopy (XPS) is demonstrated using single-layer graphene membranes as photoelectron-transparent barriers that sustain pressure differences in excess of 6 orders of magnitude. The graphene serves as a support for catalyst nanoparticles under atmospheric pressure reaction conditions (up to 1.5 bar), where XPS allows the oxidation state of Cu nanoparticles and gas phase species to be simultaneously probed. We thereby observe that the Cu(2+) oxidation state is stable in O2 (1 bar) but is spontaneously reduced under vacuum. We further demonstrate the detection of various gas-phase species (Ar, CO, CO2, N2, O2) in the pressure range 10-1500 mbar including species with low photoionization cross sections (He, H2). Pressure-dependent changes in the apparent binding energies of gas-phase species are observed, attributable to changes in work function of the metal-coated grids supporting the graphene. We expect atmospheric pressure XPS based on this graphene membrane approach to be a valuable tool for studying nanoparticle catalysis.