Site-specific fabrication of Fe particles for carbon nanotube growth

Resistance of Boron Nitride Nanotubes to Radiation-Induced Oxidation

We present unprecedented results on the damage thresholds and pathways for boron nitride nanotubes (BNNT) under the influence of energetic electrons in an oxidative gas environment, using an environmental aberration-corrected electron microscope over a range of oxygen pressures. We observe a damage cascade process that resists damage until a higher electron dose, compared with carbon nanotubes, initiating at defect-free BNNT sidewalls and proceeding through the conversion from crystalline nanotubes to amorphous boron nitride (BN), resisting oxidation throughout. We compare with prior results on the oxidation of carbon nanotubes and present a model that attributes the onset of damage in both cases to a physisorbed oxygen layer that reduces the threshold for damage onset. Surprisingly, increased temperatures offer protection against damage, as do electron dose rates that significantly exceed the oxygen dose rates, and our model attributes both effects to a physisorbed oxygen population.

In Situ TEM Characterization and Modulation for Phase Engineering of Nanomaterials

Solid-state phase transformation is an intriguing phenomenon in crystalline or noncrystalline solids due to the distinct physical and chemical properties that can be obtained and modified by phase engineering. Compared to bulk solids, nanomaterials exhibit enhanced capability for phase engineering due to their small sizes and high surface-to-volume ratios, facilitating various emerging applications. To establish a comprehensive atomistic understanding of phase engineering, in situ transmission electron microscopy (TEM) techniques have emerged as powerful tools, providing unprecedented atomic-resolution imaging, multiple characterization and stimulation mechanisms, and real-time integrations with various external fields. In this Review, we present a comprehensive overview of recent advances in in situ TEM studies to characterize and modulate nanomaterials for phase transformations under different stimuli, including mechanical, thermal, electrical, environmental, optical, and magnetic factors. We briefly introduce crystalline structures and polymorphism and then summarize phase stability and phase transformation models. The advanced experimental setups of in situ techniques are outlined and the advantages of in situ TEM phase engineering are highlighted, as demonstrated via several representative examples. Besides, the distinctive properties that can be obtained from in situ phase engineering are presented. Finally, current challenges and future research opportunities, along with their potential applications, are suggested.

Production of H2 and CNM from biogas decomposition using biosolids-derived biochar and the application of the CNM-coated biochar for PFAS adsorption

Anaerobic digestion is a popular unit operation in wastewater treatment to degrade organic contaminants, thereby generating biogas (methane-rich gas stream). Catalytic decomposition of the biogas could be a promising upcycling approach to produce renewable hydrogen and sequester carbon in the form of carbon nanomaterials (CNMs). Biosolids are solid waste generated during the wastewater treatment process, which can be valorised to biochar via pyrolysis. This work demonstrates the use of biosolids-derived biochar compared with ilmenite as catalysts for biogas decomposition to hydrogen and CNMs. Depending on the reaction time, biosolids-derived biochar achieved a CH₄ and CO₂ conversion of 50-70 % and 70-90 % at 900 °C with a weight hourly space velocity (WHSV) of 1.2 Lg^-1h^-1. The high conversion rate was attributed to the formation of amorphous carbon on the biochar surface, where the carbon deposits acted as catalysts and substrates for the further decomposition of CH₄ and CO₂. Morphological characterisation of biochar after biogas decomposition revealed the formation of high-quality carbon nanospheres (200-500 nm) and carbon nanofibres (10-100 nm) on its surface. XRD pattern and Raman spectroscopy also signified the presence of graphitic structures with I_D/I_G ratio of 1.19, a reduction from 1.33 in the pristine biochar. Finally, the produced CNM-loaded biochar was tested for PFAS adsorption from contaminated wastewater. A removal efficiency of 79 % was observed for CNM-coated biochar which was 10-60 % higher than using biochar and ilmenite alone. This work demonstrated an integrated approach for upcycling waste streams generated in wastewater treatment facilities.

Metallocene-Filled Single-Walled Carbon Nanotube Hybrids

In this paper, the growth mechanism, structure, growth processes, growth kinetics, and optical, vibronic and electronic properties of metallocene-filled single-walled carbon nanotubes (SWCNTs) are considered. A description of the procedures used to fill the nanotubes is provided. An investigation of doping effects on metallicity-mixed SWCNTs filled with metallocenes by Raman spectroscopy, near edge X-ray absorption fine structure spectroscopy, photoemission spectroscopy, and optical absorption spectroscopy is described. The studies of doping effects on metallicity-sorted SWCNTs filled with metallocenes are discussed. Doping effects in metallicity-mixed and sorted SWCNTs upon the chemical transformation of encapsulated molecules are analyzed. A discussion of the modification of the electronic properties of filled SWCNTs is presented. Applications of metallocene-filled SWCNTs in electrochemistry, thermoelectric power generation, chemical sensors, and magnetic recording are discussed.

Enhanced Hydrogen Evolution Reaction over Co Nanoparticles Embedded N-Doped Carbon Nanotubes Electrocatalyst with Zn as an Accelerant

The rational design for transition metals-based carbon nano-materials as efficient electrocatalysts still remains a crucial challenge for economical electrochemical hydrogen production. Carbon nanotubes (CNTs) as attractive electrocatalysts are typically activated by non-metal dopant to promote catalytic performance. Metals doping or metal/non-metal co-doping of CNTs, however, are rarely explored. Herein, this work rationally designs bimetal oxide templates of ZnCo₂ O₄ for heterogeneously doping Zn and N into Co nanoparticles embedded carbon nanotubes (Co@Zn-N-CNTs). During the formation of CNTs, Zn atoms volatilize from ZnCo₂ O₄ and in situ dope into the carbon skeleton. In particular, owing to the low electronegativity of Zn, the electrons aptly transfer from Zn to carbon atoms, which generate a high electron density for the carbon layers and offer more preponderant catalytic sites for hydrogen reduction. The Co@Zn-N-CNTs catalyst exhibits enhanced hydrogen evolution reaction activity in 0.5 m H₂ SO₄ electrolyte, with a low onset potential of -20 mV versus RHE at 1 mA cm^-2 , an overpotential of 67 mV at 10 mA cm^-2 , a small Tafel slope of 52.1 mV dec^-1 , and persistent long-term stability. This study provides brand-new insights into the utilization of Zn as electronic regulator and activity promoter toward the design of high-efficiency electrocatalysts.

Precise Identification of the Active Phase of Cobalt Catalyst for Carbon Nanotube Growth by In Situ Transmission Electron Microscopy

Revealing the active phase and structure of catalyst nanoparticles (NPs) is crucial for understanding the growth mechanism and realizing the controlled synthesis of carbon nanotubes (CNTs). However, due to the high temperature and complex environment during CNT growth, precise identification of the active catalytic phase remains a great challenge. We investigated the phase evolution of cobalt (Co) catalyst NPs during the incubation, nucleation, and growth stages of CNTs under near-atmospheric pressure using an in situ close-cell environmental transmission electron microscope (ETEM). Strict statistical analysis of the electron diffractograms was performed to accurately identify the phases of the catalyst NPs. It was found that the NPs belong to an orthorhombic Co₃C phase that remained unchanged during CNT growth, with errors in lattice spacing <5% and in angle <2°, despite changes in their morphology and orientation. Theoretical calculations further confirm that Co₃C is the thermodynamically preferred phase during CNT growth, with the supply of carbon atoms through the surface and NP-CNT interfacial diffusion.

A structure and activity relationship for single-walled carbon nanotube growth confirmed by in situ observations and modeling

The structure and phase transformation of a cobalt (Co) catalyst, during single walled carbon nanotube (SWCNT) growth, is elucidated for inactive, active and deactivated nanoparticles by in situ imaging using an environmental transmission electron microscope. During nanotube growth, the structure was analyzed using Miller indices to determine the types of planes that favor anchoring or liftoff of nanotubes from the Co catalyst. Density functional theory was further applied to model the catalyst interactions to compare the work of adhesion of the catalyst's faceted planes to understand the interactions of different Miller planes with the graphene structure. Through in-depth studies of multiple distinct Co nanoparticles, we established a dominant nanoparticle phase for SWCNT growth. In addition, we identified the preferred lattice planes and a threshold for work of adhesion to allow the anchoring and liftoff of SWCNTs.

Chirality Pure Carbon Nanotubes: Growth, Sorting, and Characterization

Single-walled carbon nanotubes (SWCNTs) have been attracting tremendous attention owing to their structure (chirality) dependent outstanding properties, which endow them with great potential in a wide range of applications. The preparation of chirality-pure SWCNTs is not only a great scientific challenge but also a crucial requirement for many high-end applications. As such, research activities in this area over the last two decades have been very extensive. In this review, we summarize recent achievements and accumulated knowledge thus far and discuss future developments and remaining challenges from three aspects: controlled growth, postsynthesis sorting, and characterization techniques. In the growth part, we focus on the mechanism of chirality-controlled growth and catalyst design. In the sorting part, we organize and analyze existing literature based on sorting targets rather than methods. Since chirality assignment and quantification is essential in the study of selective preparation, we also include in the last part a comprehensive description and discussion of characterization techniques for SWCNTs. It is our view that even though progress made in this area is impressive, more efforts are still needed to develop both methodologies for preparing ultrapure (e.g., >99.99%) SWCNTs in large quantity and nondestructive fast characterization techniques with high spatial resolution for various nanotube samples.

Nanoscale Patterning of Carbon Nanotubes: Techniques, Applications, and Future

Carbon nanotube (CNT) devices and electronics are achieving maturity and directly competing or surpassing devices that use conventional materials. CNTs have demonstrated ballistic conduction, minimal scaling effects, high current capacity, low power requirements, and excellent optical/photonic properties; making them the ideal candidate for a new material to replace conventional materials in next-generation electronic and photonic systems. CNTs also demonstrate high stability and flexibility, allowing them to be used in flexible, printable, and/or biocompatible electronics. However, a major challenge to fully commercialize these devices is the scalable placement of CNTs into desired micro/nanopatterns and architectures to translate the superior properties of CNTs into macroscale devices. Precise and high throughput patterning becomes increasingly difficult at nanoscale resolution, but it is essential to fully realize the benefits of CNTs. The relatively long, high aspect ratio structures of CNTs must be preserved to maintain their functionalities, consequently making them more difficult to pattern than conventional materials like metals and polymers. This review comprehensively explores the recent development of innovative CNT patterning techniques with nanoscale lateral resolution. Each technique is critically analyzed and applications for the nanoscale-resolution approaches are demonstrated. Promising techniques and the challenges ahead for future devices and applications are discussed.

Isolating the Roles of Hydrogen Exposure and Trace Carbon Contamination on the Formation of Active Catalyst Populations for Carbon Nanotube Growth

Limited understanding of the factors influencing the yield of carbon nanotubes (CNTs) relative to the number of catalyst particles remains an important barrier to their large-scale production with high quality, and to tailoring CNT properties for applications. This lack of understanding is evident in the frequent use of Edisonian approaches to give high-yield CNT growth, and in the sometimes-confusing influence of trace residues on the reactor walls. In order to create conditions wherein CNT yield is reproducible and to enable large-scale and reliable CNT synthesis, it is imperative to understand-fundamentally-how these common practices impact catalytic activity and thus CNT number density. Herein, we use ambient pressure-X-ray photoelectron spectroscopy (AP-XPS) to reveal the influence of carbon and hydrogen on the coupling between catalyst reduction and CNT nucleation, from an iron catalyst film. We observe a positive correlation between the degree of catalyst reduction and the density of vertically aligned CNTs (forests), verifying that effective catalyst reduction is critical to CNT nucleation and to the resulting CNT growth yield. We demonstrate that the extent of catalyst reduction is the reason for low CNT number density and for lack of self-organization, lift-off, and growth of CNT forests. We also show that hydrocarbon byproducts from consecutive growths can facilitate catalyst reduction and increase CNT number density significantly. These findings suggest that common practices used in the field-such as reactor preconditioning-aid in the reduction of the catalyst population, thus improving CNT number density and enabling the growth of dense forests. Our results also motivate future work using AP-XPS and complementary metrology tools to optimize CNT growth conditions according to the catalyst chemical state.

Growth and Termination Dynamics of Multiwalled Carbon Nanotubes at Near Ambient Pressure: An in Situ Transmission Electron Microscopy Study

Understanding the growth mechanism of carbon nanotubes (CNTs) has been long pursued since its discovery. With recent integration of in situ techniques into the study of CNT growth, important insights about the growth mechanism of CNT have been generated, which have improved our understanding significantly. However, previous in situ experiments were mainly conducted at low pressures which were far from the practical conditions. Direct information about the growth dynamics under relevant conditions is still absent and thus is highly desirable. In this work, we report atomic-scale observations of multiwalled CNT (MWCNT) growth and termination at near ambient pressure by in situ transmission electron microscopy. On the basis of the real-time imaging, we are able to reveal that the working catalyst is constantly reshaping at its apex during catalyzing CNT growth, whereas at the base the catalyst remains faceted and barely shows any morphological change. The active catalyst is identified as crystalline Fe₃C, based on lattice fringes that can be imaged during growth. However, the oscillatory growth behavior of the CNT and the structural dynamics of the apex area strongly indicate that the carbon concentration in the catalyst particle is fluctuating during the course of CNT growth. Extended observations further reveal that the catalyst splitting can occur: whereas the majority of the catalyst stays at the base and continues catalyzing CNT growth, a small portion of it gets trapped inside of the growing nanotube. The catalyst splitting can take place multiple times, leading to shrinkage of both, catalyst size and diameter of CNT, and finally the growth termination of CNT due to the full coverage of the catalyst by carbon layers. Additionally, in situ observations show two more scenarios for the growth termination, that is, out-migration of the catalyst from the growing nanotube induced by (i) Oswald ripening and (ii) weakened adhesion strength between the catalyst and CNT.

Low-Temperature Growth of Carbon Nanotubes Catalyzed by Sodium-Based Ingredients

Synthesis of low-dimensional carbon nanomaterials such as carbon nanotubes (CNTs) is a key driver for achieving advances in energy storage, computing, and multifunctional composites, among other applications. Here, we report high-yield thermal chemical vapor deposition (CVD) synthesis of CNTs catalyzed by reagent-grade common sodium-containing compounds, including NaCl, NaHCO₃ , Na₂ CO₃ , and NaOH, found in table salt, baking soda, and detergents, respectively. Coupled with an oxidative dehydrogenation reaction to crack acetylene at reduced temperatures, Na-based nanoparticles have been observed to catalyze CNT growth at temperatures below 400 °C. Ex situ and in situ transmission electron microscopy (TEM) reveal unique CNT morphologies and growth characteristics, including a vaporizing Na catalyst phenomenon that we leverage to create CNTs without residual catalyst particles for applications that require metal-free CNTs. Na is shown to synthesize CNTs on numerous substrates, and as the first alkali group metal catalyst demonstrated for CNT growth, holds great promise for expanding the understanding of nanocarbon synthesis.

Localized growth of carbon nanotubes via lithographic fabrication of metallic deposits

We report on the fabrication of carbon nanotubes (CNTs) at predefined positions and controlled morphology, for example, as individual nanotubes or as CNT forests. Electron beam induced deposition (EBID) with subsequent autocatalytic growth (AG) was applied to lithographically produce catalytically active seeds for the localized growth of CNTs via chemical vapor deposition (CVD). With the precursor Fe(CO)₅ we were able to fabricate clean iron deposits via EBID and AG. After the proof-of-principle that these Fe deposits indeed act as seeds for the growth of CNTs, the influence of significant EBID/AG parameters on the deposit shape and finally the yield and morphology of the grown CNTs was investigated in detail. Based on these results, the parameters could be optimized such that EBID point matrixes (6 × 6) were fabricated on a silica surface whereby at each predefined site only one CNT was produced. Furthermore, the localized fabrication of CNT forests was targeted and successfully achieved on an Al₂O₃ layer on a silicon sample. A peculiar lift-up of the Fe seed structures as “flakes” was observed and the mechanism was discussed. Finally, a proof-of-principle was presented showing that EBID deposits from the precursor Co(CO)₃NO are also very effective catalysts for the CNT growth. Even though the metal content (Co) of the latter is reduced in comparison to the Fe deposits, effective CNT growth was observed for the Co-containing deposits at lower CVD temperatures than for the corresponding Fe deposits.

Comparison of Pd electron beam induced deposition using two precursors and an oxygen purification strategy

Focused electron beam induced deposition (FEBID) allows the creation of nanoscale structures through dissociation of an organo-metallic precursor by electrons at the beam impact point. The deposition of Pd can be interesting for its catalytic behavior and ability to contact carbon based materials. Two precursors were investigated-Pd(hfac)₂ and (Cp)Pd(allyl)-and two deposition methods: with and without an in situ oxygen purification process. The deposition parameters can be tuned for the Pd(hfac)₂ precursor to provide a deposition with 23 ± 2 at.% of Pd and a main component of C at 51 ± 3 at.% and minor components of O and F. An in situ purification process using O₂ was much faster than expected and improved the Pd content to up to >65 at.% while reducing the C to ∼20 at.%, and avoiding the oxidation of Pd. The resistivity was ∼100 μOhm · cm and compares favorably with a bulk value of 10 μOhm · cm. The (Cp)Pd(allyl) precursor is interesting because it does not release fluorine during the deposition and hence it does not etch a possible substrate. Its FEBID deposition had a composition of 26 ± 5 at.% of Pd with 74 ± 5 at.% of C. The O₂ purification process can improve the Pd content up to ∼60 at.% while reducing C to <20 at.%, but also increasing the O content to 18 at%, which was released afterwards. The best resistivity was measured at ∼1000 μOhm · cm, although better values can be anticipated for longer post treatment times.

Direct evidence of atomic-scale structural fluctuations in catalyst nanoparticles

Rational catalyst design requires an atomic scale mechanistic understanding of the chemical pathways involved in the catalytic process. A heterogeneous catalyst typically works by adsorbing reactants onto its surface, where the energies for specific bonds to dissociate and/or combine with other species (to form desired intermediate or final products) are lower. Here, using the catalytic growth of single-walled carbon nanotubes (SWCNTs) as a prototype reaction, we show that the chemical pathway may in-fact involve the entire catalyst particle, and can proceed via the fluctuations in the formation and decomposition of metastable phases in the particle interior. We record in situ and at atomic resolution, the dynamic phase transformations occurring in a Cobalt catalyst nanoparticle during SWCNT growth, using a state-of-the-art environmental transmission electron microscope (ETEM). The fluctuations in catalyst carbon content are quantified by the automated, atomic-scale structural analysis of the time-resolved ETEM images and correlated with the SWCNT growth rate. We find the fluctuations in the carbon concentration in the catalyst nanoparticle and the fluctuations in nanotube growth rates to be of complementary character. These findings are successfully explained by reactive molecular dynamics (RMD) simulations that track the spatial and temporal evolution of the distribution of carbon atoms within and on the surface of the catalyst particle. We anticipate that our approach combining real-time, atomic-resolution image analysis and molecular dynamics simulations will facilitate catalyst design, improving reaction efficiencies and selectivity towards the growth of desired structure.

Investigation of growth dynamics of carbon nanotubes

The synthesis of single-walled carbon nanotubes (SWCNTs) with defined properties is required for both fundamental investigations and practical applications. The revealing and thorough understanding of the growth mechanism of SWCNTs is the key to the synthesis of nanotubes with required properties. This paper reviews the current status of the research on the investigation of growth dynamics of carbon nanotubes. The review starts with the consideration of the peculiarities of the growth mechanism of carbon nanotubes. The physical and chemical states of the catalyst during the nanotube growth are discussed. The chirality selective growth of nanotubes is described. The main part of the review is dedicated to the analysis and systematization of the reported results on the investigation of growth dynamics of nanotubes. The studies on the revealing of the dependence of the growth rate of nanotubes on the synthesis parameters are reviewed. The correlation between the lifetime of catalyst and growth rate of nanotubes is discussed. The reports on the calculation of the activation energy of the nanotube growth are summarized. Finally, the growth properties of inner tubes inside SWCNTs are considered.

Nucleation of graphene and its conversion to single-walled carbon nanotubes

We use an environmental transmission electron microscope to record atomic-scale movies showing how carbon atoms assemble together on a catalyst nanoparticle to form a graphene sheet that progressively lifts-off to convert into a nanotube. Time-resolved observations combined with theoretical calculations confirm that some nanoparticle facets act like a vice-grip for graphene, offering anchoring sites, while other facets allow the graphene to lift-off, which is the essential step to convert into a nanotube.

Electron induced surface reactions of organometallic metal(hfac)₂ precursors and deposit purification

The elementary processes associated with electron beam-induced deposition (EBID) and post-deposition treatment of structures created from three metal(II)(hfac)2 organometallic precursors (metal = Pt, Pd, Cu; hfac = CF3C(O)CHC(O)CF3) have been studied using surface analytical techniques. Electron induced reactions of adsorbed metal(II)(hfac)2 molecules proceeds in two stages. For comparatively low electron doses (doses <1 × 10(17) e(-)/cm(2)) decomposition of the parent molecules leads to loss of carbon and oxygen, principally through the formation of carbon monoxide. Fluorine and hydrogen atoms are also lost by electron stimulated C-F and C-H bond cleavage, respectively. Collectively, these processes are responsible for the loss of a significant fraction (≥ 50%) of the oxygen and fluorine atoms, although most (>80%) of the carbon atoms remain. As a result of these various transformations the reduced metal atoms become encased in an organic matrix that is stabilized toward further electron stimulated carbon or oxygen loss, although fluorine and hydrogen can still desorb in the second stage of the reaction under the influence of sustained electron irradiation as a result of C-F and C-H bond cleavage, respectively. This reaction sequence explains why EBID structures created from metal(II)(hfac)2 precursors in electron microscopes contain reduced metal atoms embedded within an oxygen-containing carbonaceous matrix. Except for the formation of copper fluoride from Cu(II)(hfac)2, because of secondary reactions between partially reduced copper atoms and fluoride ions, the chemical composition of EBID films and behavior of metal(II)(hfac)2 precursors was independent of the transition metal's chemical identity. Annealing studies of EBID structures created from Pt(II)(hfac)2 suggest that the metallic character of deposited Pt atoms could be increased by using post deposition annealing or elevated substrate temperatures (>25 °C) during deposition. By exposing EBID structures created from Cu(II)(hfac)2 to atomic oxygen followed by atomic hydrogen, organic contaminants could be abated without annealing.

Kinetics of laser-assisted carbon nanotube growth

Laser-assisted chemical vapour deposition (CVD) growth is an attractive mask-less process for growing locally aligned carbon nanotubes (CNTs) in selected places on temperature sensitive substrates. The nature of the localized process results in fast carbon nanotube growth with high experimental throughput. Here, we report on the detailed investigation of growth kinetics related to physical and chemical process characteristics. Specifically, the growth kinetics is investigated by monitoring the dynamical changes in reflected laser beam intensity during growth. Benefiting from the fast growth and high experimental throughput, we investigate a wide range of experimental conditions and propose several growth regimes. Rate-limiting steps are determined using rate equations linked to the proposed growth regimes, which are further characterized by Raman spectroscopy and Scanning Electron Microscopy (SEM), therefore directly linking growth regimes to the structural quality of the CNTs. Activation energies for the different regimes are found to be in the range of 0.3-0.8 eV.

Incremental growth of short SWNT arrays by pulsed chemical vapor deposition

Very short arrays of continuous single-wall carbon nanotubes (SWNTs) are grown incrementally in steps as small as 25 nm using pulsed chemical vapor deposition (CVD). In-situ optical extinction measurements indicate that over 98% of the nanotubes reinitiate growth on successive gas pulses, and high-resolution transmission electron microscopy (HR-TEM) images show that the SWNTs do not exhibit segments, caps, or noticeable sidewall defects resulting from repeatedly stopping and restarting growth. Time-resolved laser reflectivity (3-ms temporal resolution) is used to record the nucleation and growth kinetics for each fast (0.2 s) gas pulse and to measure the height increase of the array in situ, providing a method to incrementally grow short nanotube arrays to precise heights. Derivatives of the optical reflectivity signal reveal distinct temporal signatures for both nucleation and growth kinetics, with their amplitude ratio on the first gas pulse serving as a good predictor for the evolution of the growth of the nanotube ensemble into a coordinated array. Incremental growth by pulsed CVD is interpreted in the context of autocatalytic kinetic models as a special processing window in which a sufficiently high flux of feedstock gas drives the nucleation and rapid growth phases of a catalyst nanoparticle ensemble to occur within the temporal period of the gas pulse, but without inducing growth termination.

Growth kinetics of vertically aligned carbon nanotube arrays in clean oxygen-free conditions

Vertically aligned carbon nanotubes (CNTs) are an important technological system, as well as a fascinating system for studying basic principles of nanomaterials synthesis; yet despite continuing efforts for the past decade many important questions about this process remain largely unexplained. We present a series of parametric ethylene chemical vapor deposition growth studies in a "hot-wall" reactor using ultrapure process gases that reveal the fundamental kinetics of the CNT growth. Our data show that the growth rate is proportional to the concentration of the carbon feedstock and monotonically decreases with the concentration of hydrogen gas and that the most important parameter determining the rate of the CNT growth is the production rate of active carbon precursor in the gas phase reaction. The growth termination times obtained with the purified gas mixtures were strikingly insensitive to variations in both hydrogen and ethylene pressures ruling out the carbon encapsulation of the catalyst as the main process termination cause.

Carbon diffusion from methane into walls of carbon nanotube through structurally and compositionally modified iron catalyst

To understand diffusion processes occurring inside Fe catalysts during multiwall carbon nanotube (MWCNT) growth, catalysts were studied using atomic-resolution scanning transmission electron microscopy combined with electron energy-loss spectroscopy. Nanotube walls emanate from structurally modified and chemically complex catalysts that consist of cementite and a 5 nm amorphous FeOx cap separated by a 2-3 nm thick carbon-rich region that also contains Fe and O (a-C:FexOy). Nonuniform distribution of carbon atoms throughout the catalyst base reveals that carbon molecules from the gas phase decompose near the catalyst multisection junction, where the MWCNT walls terminate. Formation of the a-C:FexOy region provides the essential carbon source for MWCNT growth. Two different carbon diffusion mechanisms are responsible for the growth of the inner and outer walls of each MWCNT.

Evaluation of the role of Au in improving catalytic activity of Ni nanoparticles for the formation of one-dimensional carbon nanostructures

In situ dynamic imaging, using an environmental transmission electron microscope, was employed to evaluate the catalytic activity of Au/SiO(2), Ni/SiO(2), and Au-Ni/SiO(2) nanoparticles for the formation of one-dimensional (1-D) carbon nanostructures such as carbon nanofibers (CNFs) and nanotubes (CNTs). While pure-Au thin-film samples were inactive for carbon deposition at 520 °C in 0.4 Pa of C(2)H(2), multiwalled CNTs formed from Ni thin films samples under these conditions. The number of nanoparticles active for CNF and CNT formation increased for thin films containing 0.1 mol fraction and 0.2 mol fraction of Au but decreased as the overall Au content in thin films was increased above 0.5 mol fraction. Multiwalled CNTs formed with a root growth mechanism for pure Ni samples, while with the addition of 0.1 mol fraction or 0.2 mol fraction of Au, CNFs were formed via a tip growth mechanism at 520 °C. Single-walled CNTs formed at temperatures above 600 °C in samples doped with less than 0.2 mol fraction of Au. Ex situ analysis via high-resolution scanning transmission electron microscopy (STEM) and energy-dispersive X-ray spectroscopy (EDS) revealed that catalytically active particles exhibit a heterogeneous distribution of Au and Ni, where only a small fraction of the overall Au content was found in the portion of each particle actively involved in the nucleation of graphitic layers. Instead, the majority of the Au was found to be segregated to an inactive capping structure at one the end of the particles. Using density-functional theory calculations, we show that the activation energy for bulk diffusion of carbon in Ni reduces from ≈1.62 eV for pure Ni to 0.07 eV with the addition of small amounts (≈0.06 mol fraction) of Au. This suggests that the enhancement of C diffusion through the bulk of the particles may be responsible for improving the number of particles active for nucleating the 1-D carbon nanostructures and thereby the yield.

Orientation and morphological evolution of catalyst nanoparticles during carbon nanotube growth

We examined the structure, morphology, and orientation of catalyst nanoparticles used for seeding and growing multiwall carbon nanotubes (MWCNTs) by plasma enhanced chemical vapor deposition in CH4/H2 gas mixtures. Iron catalyst nanocrystals are converted to Fe3C in CH4/H2 plasmas and the MWCNTs grow from Fe3C nanocrystals. Initially faceted and equiaxed catalyst nanocrystals are distorted and elongated significantly once a tubular CNT structure is formed around the catalyst particles. Eventually, catalysts deform into elongated tear-drop shapes. Once this morphology forms, CNT structures produced are straight and have uniform diameters. Surprisingly, the Fe3C nanocrystals located inside the base of well-graphitized nanotubes do not exhibit a preferred orientation relative to the nanotube axis. Catalyst nanocrystals in a variety of orientations relative to the nanotube axis still produce well-graphitized nanotubes with similar diameters and structures.

Atomic-scale analysis on the role of molybdenum in iron-catalyzed carbon nanotube growth

We have elucidated the synergetic role played by molybdenum in iron-catalyzed chemical vapor deposition growth of carbon nanotubes (CNTs) by in situ environmental transmission electron microscopy. Molybdenum can be well accommodated by Fe-based carbide nanoparticle catalysts of M(23)C(6)-type structure (M = Fe and Mo). We have also shown that molybdenum suppresses the nucleation of iron compounds that are known to exhibit no catalytic activity for the growth of CNTs.