Growth of ultrahigh density single-walled carbon nanotube forests by improved catalyst design

Construction of Medusa-Like Adhesive Carbon Nanotube Array Induced by Deformation of Alumina Sheets

To change the binary structure of nanotube and nanotube array in vertically aligned carbon nanotube arrays, this work deposits regularly arranged amorphous alumina sheets on the classical array growth catalyst (10 nm-thick alumina and 2 nm-thick iron) and obtains an array similar to the Medusa head. Subsequent experiments revealed that these alumina sheets show both unstable and stable qualities during growth: unstable in that they thermally deform and change their newly discovered characteristics of blocking carbon source diffusion, which regulates the nanotube growth order in specific areas; stable in that they withstand the deformation caused by heat and sequential growth of nanotubes, serving as a substrate and buffer layer for Medusa's hair, i.e., nanotube bundles on the array surface. Their combination splits this binary structure into a tertiary architecture consisting of nanotubes, nanotube bundles, and the array spanning nano-, micro-, and milli-meter. Benefiting from this structure, this array exhibits a unique near-isotropic adhesion characteristic compared to existing reports and outperforms classical and patterned arrays with the same classical catalyst and growth conditions.

Emerging enzyme-based nanocomposites for catalytic biomedicine

With the promising advances in nanomedicine, numerous strategies have emerged for the diagnosis and treatment of diseases. Among them, enzyme-based multifunctional nanocomposites have attracted a great deal of attention in the field of catalytic biomedicine. These nanocomposites with high catalytic activity are capable of converting low/non-toxic substances into therapeutic ones, thus realizing highly efficient, site-specific therapy with minimal side effects. Enzyme-based nanocomposites for catalytic biomedicine are mainly divided into three types: (i) natural-enzyme based nanocomposites; (ii) artificial-nanozyme based nanocomposites; and (iii) nanocomposites of natural-enzymes and nanozymes. In this review, we discuss key aspects of enzyme-based catalytic biomedicine, including the construction of enzyme-based nanocomposites, their unique properties and applications in catalytic biomedicine. We also highlight the main challenges faced in this field, and provide relevant guidelines for the rational design and extensive application of enzyme-based nanocomposites from our point of view.

Conducting Interface for Efficient Growth of Vertically Aligned Carbon Nanotubes: Towards Nano-Engineered Carbon Composite

Vertically aligned carbon nanotubes (VACNT) are manufactured nanomaterials with excellent properties and great potential for numerous applications. Recently, research has intensified toward achieving VACNT synthesis on different planar and non-planar substrates of various natures, mainly dependent on the user-defined application. Indeed, VACNT growth has to be adjusted and optimized according to the substrate nature and shape to reach the requirements for the application envisaged. To date, different substrates have been decorated with VACNT, involving the use of diffusion barrier layers (DBLs) that are often insulating, such as SiO₂ or Al₂O₃. These commonly used DBLs limit the conducting and other vital physico-chemical properties of the final nanomaterial composite. One interesting route to improve the contact resistance of VACNT on a substrate surface and the deficient composite properties is the development of semi-/conducting interlayers. The present review summarizes different methods and techniques for the deposition of suitable conducting interfaces and controlled growth of VACNT on diverse flat and 3-D fibrous substrates. Apart from exhibiting a catalytic efficiency, the DBL can generate a conducting and adhesive interface involving performance enhancements in VACNT composites. The abilities of different conducting interlayers are compared for VACNT growth and subsequent composite properties. A conducting interface is also emphasized for the synthesis of VACNT on carbonaceous substrates in order to produce cost-effective and high-performance nano-engineered carbon composites.

Formation of Thermally Stable, High-Areal-Density, and Small-Diameter Catalyst Nanoparticles via Intermittent Sputtering Deposition for the High-Density Growth of Carbon Nanotubes

We report the formation of thermally stable catalyst nanoparticles via intermittent sputtering deposition to prevent the agglomeration of the nanoparticles during thermal chemical vapor deposition (CVD) and for the high-density growth of carbon nanotubes (CNTs). The preparation of high-areal-density and small-diameter catalyst nanoparticles on substrates for the high-density growth of CNTs is still a challenging issue because surface diffusion and Ostwald ripening of the nanoparticles induce agglomeration, which results in the low-density growth of large-diameter CNTs during high-temperature thermal CVD. Enhancing the adhesion of nanoparticles or suppressing their diffusion on the substrate to retain a small particle diameter is desirable for the preparation of thermally stable, high-areal-density, and small-diameter catalyst nanoparticles. The intermittent sputtering method was employed to deposit Ni and Fe metal nanoparticles on a substrate for the synthesis of high-areal-density CNTs for Fe nanoparticle catalyst films. The metal particles deposited via intermittent sputtering with an interval time of over 30 s maintained their areal densities and diameters during the thermal CVD process in a vacuum for CNT synthesis. An interval of over 30 s was expected to oxidize the metal particles, which resulted in thermal stability during the CVD process. The intermittent sputtering method is thus a candidate process for the preparation of thermally stable catalyst films for the growth of a high density of long CNTs, which can be combined with the present CNT production process.

W Clusters In Situ Assisted Synthesis of Layered Carbon Nanotube Arrays on Graphene Achieving High-Rate Performance

W atoms/clusters are employed to in situ assist the development of layered vertically aligned carbon nanotube arrays (VACNTs) through hot-filament-assisted chemical vapor deposition (HFCVD) with liquid binary Fe₃O₄/AlO_x catalysts. The hot W filament was utilized to in situ evaporate atomic W and form W clusters on Fe catalysts, which have a strong impact on the growth of layered VACNT arrays. The migration and Ostwald ripening of Fe catalysts are found to be suppressed immediately with more W clusters deposition during CNT growth. Through controlling the deposition of W clusters, the electrochemical energy storage performance of as-prepared layered VACNT arrays is also tunable as electrodes of ion-based supercapacitors. The layered VACNT arrays can achieve a high capacity of 83.1 mF cm^-2 and possess desirable rate performance due to the suitable hot filament condition (55 W for 90 s). This work provides a new perspective to in-depth understand the behavior of W filament during HFCVD and the significant role of the in situ generated W clusters on the growth of CNTs by maintaining the catalytic activity and structure of catalysts.

Kinetics of Carbon Nanotubes and Graphene Growth on Iron and Steel: Evidencing the Mechanisms of Carbon Formation

Carbon formation on steel has recently become an active research area with several important applications, using either carbon nanotubes (CNTs) or graphene structures. The production of vertically aligned CNT (VACNT) forests with combined metals has been explored with important results. Detailed kinetics is the best approach to understand a mechanism. The growth behavior seems complex but can be simplified through the knowledge of the three more common alternative reaction mechanisms/routes. The time required to optimize the production and properties might be reduced. The mechanistic proposal reported in 1971 was better explained recently. The volcano shape Arrhenius plot reported is observed only when Fe, Co, and Ni are used as reaction catalysts. Other metals are catalytically active at higher temperatures, following a different route, which does not require surface catalysis decomposition of the reactive gas. C₂H₂ and low olefins react well, but CH₄ is not reactive via this surface catalysis route. Optimizing production of CNTs, research work is usually based on previous experience, but solid-state science-based studies are available.

Effects of high temperature treatment of carbon nanotube arrays on graphite: increased crystallinity, anchoring and inter-tube bonding

Thermal treatment of carbon nanotubes (CNTs) can significantly improve their mechanical, electrical and thermal properties due to reduced defects and increased crystallinity. In this work we investigate the effect of annealing at 3000 °C of vertically aligned CNT arrays synthesized by chemical vapor deposition (CVD) on graphite. Raman measurements show a drastically reduced amount of defects and, together with transmission electron microscope (TEM) diffraction measurements, an increased average crystallite size of around 50%, which corresponds to a 124% increase in Young's modulus. We also find a tendency for CNTs to bond to each other with van der Waals (vdW) forces, which causes individual CNTs to closely align with each other. This bonding causes a densification effect on the entire CNT array, which appears at temperatures >1000 °C. The densification onset temperature corresponds to the thermal decomposition of oxygen containing functional groups, which otherwise prevents close enough contact for vdW bonding. Finally, the remaining CVD catalyst on the bottom of the CNT array is evaporated during annealing, enabling direct anchoring of the CNTs to the underlying graphite substrate.

Synthesis of Vertical Carbon Nanotube Interconnect Structures Using CMOS-Compatible Catalysts

Synthesis of the vertically aligned carbon nanotubes (CNTs) using complementary metal-oxide-semiconductor (CMOS)-compatible methods is essential to integrate the CNT contact and interconnect to nanoscale devices and ultra-dense integrated nanoelectronics. However, the synthesis of high-density CNT array at low-temperature remains a challenging task. The advances in the low-temperature synthesis of high-density vertical CNT structures using CMOS-compatible methods are reviewed. Primarily, recent works on theoretical simulations and experimental characterizations of CNT growth emphasized the critical roles of catalyst design in reducing synthesis temperature and increasing CNT density. In particular, the approach of using multilayer catalyst film to generate the alloyed catalyst nanoparticle was found competent to improve the active catalyst nanoparticle formation and reduce the CNT growth temperature. With the multilayer catalyst, CNT arrays were directly grown on metals, oxides, and 2D materials. Moreover, the relations among the catalyst film thickness, CNT diameter, and wall number were surveyed, which provided potential strategies to control the tube density and the wall density of synthesized CNT array.

Growth and Mechanics of Heterogeneous, 3D Carbon Nanotube Forest Microstructures Formed by Sequential Selective-Area Synthesis

Three-dimensional carbon nanotube (CNT) forest microstructures are synthesized using sequenced, site-specific synthesis techniques. Thin-film layers of Al₂O₃ and Al₂O₃/Fe are patterned to support film-catalyst and floating-catalyst chemical vapor deposition (CVD) in specific areas. Al₂O₃ regions support only floating-catalyst CVD, whereas regions of layered Al₂O₃/Fe support both film- and floating-catalyst CNT growth. Sequenced application of the two CVD methods produced heterogeneous 3D CNT forest microstructures, including regions of only film-catalyst CNTs, only floating-catalyst CNTs, and vertically stacked layers of each. The compressive mechanical behavior of the heterogeneous CNT forests was evaluated, with the stacked layers exhibiting two distinct buckling plateaus. Finite element simulation of the stacked layers demonstrated that the relatively soft film-catalyst CNT forests were nearly fully buckled prior to large-scale deformation of the bottom floating-catalyst CNT forests.

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.

Carbon Nanotube Assembly and Integration for Applications

Carbon nanotubes (CNTs) have attracted significant interest due to their unique combination of properties including high mechanical strength, large aspect ratios, high surface area, distinct optical characteristics, high thermal and electrical conductivity, which make them suitable for a wide range of applications in areas from electronics (transistors, energy production and storage) to biotechnology (imaging, sensors, actuators and drug delivery) and other applications (displays, photonics, composites and multi-functional coatings/films). Controlled growth, assembly and integration of CNTs is essential for the practical realization of current and future nanotube applications. This review focuses on progress to date in the field of CNT assembly and integration for various applications. CNT synthesis based on arc-discharge, laser ablation and chemical vapor deposition (CVD) including details of tip-growth and base-growth models are first introduced. Advances in CNT structural control (chirality, diameter and junctions) using methods such as catalyst conditioning, cloning, seed-, and template-based growth are then explored in detail, followed by post-growth CNT purification techniques using selective surface chemistry, gel chromatography and density gradient centrifugation. Various assembly and integration techniques for multiple CNTs based on catalyst patterning, forest growth and composites are considered along with their alignment/placement onto different substrates using photolithography, transfer printing and different solution-based techniques such as inkjet printing, dielectrophoresis (DEP) and spin coating. Finally, some of the challenges in current and emerging applications of CNTs in fields such as energy storage, transistors, tissue engineering, drug delivery, electronic cryptographic keys and sensors are considered.

Thermal Conversion of Ethanol into Carbon Nanotube Coatings with Adjusted Packing Density

The ability to control the growth of carbon nanotube (CNT) coatings with adjusted packing density is essential for the design of functional devices with an emphasized interaction with the surrounding medium. This challenge is addressed in the present study using an innovative single-pot chemical vapor deposition (CVD) process based on the thermal conversion of ethanol to CNTs. Benefitting from the relatively safe and easily bio-derived carbon source is enabled using a cobalt catalyst and a magnesium oxide promoter. The resulting innovative direct-liquid injection CVD opens up new opportunities for low-temperature CNT deposition. The simultaneous formation of a cobalt catalyst along the process results in a sustainable CNT growth that is substantially emphasized with the deposition time. Furthermore, the formation of these catalyst nanoparticles in the porous structure nucleates new CNTs and results in a substantial film densification. Relative to densely packed CNTs that feature a density exceeding 1000 mg/cm³, the investigated process enables an adjusted density from 0.1 to 20 mg/cm³ with no significant impact on the quality of the obtained multiwalled CNTs. This unprecedented control over the packing density of the CNT film paves the way toward the development of high-performance functional nanocomposite coatings.

Influence of the Sulfur Content Catalyst on the Packing Density of Carbon Nanotube Forests

For the fabrication of high-performance carbon nanotube (CNT) composites with practical applicability, the development of new methods for the controlled growth of high-aspect-ratio CNTs still constitutes a challenge. With the aim of gaining a deeper understanding of the catalytic CNT growth, in this study, the effect of the catalyst composition is investigated using different mixtures of Fe₂(SO₄)₃ and FeCl₂ as catalysts. The relationship between the catalyst chemical state and the growth behavior of CNT forests is demonstrated by evaluating the alignment, diameter, length, and areal density of the CNT forests. When the Fe₂(SO₄)₃ content is increased, the area density, the I_G/I_D ratio, and the crystallite size of the CNTs increase. Additionally, the obtained CNT forests exhibit good spinnability with increasing the sulfur content.

Mini-Review: Modeling and Performance Analysis of Nanocarbon Interconnects

As the interconnect delay exceeds the gate delay, the integrated circuit (IC) technology has evolved from a transistor-centric era to an interconnect-centric era. Conventional metallic interconnects face several serious challenges in aspects of performance and reliability. To address these issues, nanocarbon materials, including carbon nanotube (CNT) and graphene, have been proposed as promising candidates for interconnect applications. Considering the rapid development of nanocarbon interconnects, this paper is dedicated to providing a mini-review on our previous work and on related research in this field.

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.

Effect of Enhanced Thermal Stability of Alumina Support Layer on Growth of Vertically Aligned Single-Walled Carbon Nanotubes and Their Application in Nanofiltration Membranes

We investigate the thermal stability of alumina supporting layers sputtered at different conditions and its effect on the growth of aligned single-walled carbon nanotube arrays. Radio frequency magnetron sputtering of alumina under oxygen-argon atmosphere produces a Si-rich alumina alloy film on a silicon substrate. Atomic force microscopy on the annealed catalysts reveals that Si-rich alumina films are more stable than alumina layers with low Si content at the elevated temperatures at which the growth of single-walled carbon nanotubes is initiated. The enhanced thermal stability of the Si-rich alumina layer results in a narrower (< 2.2 nm) diameter distribution of the single-walled carbon nanotubes. Thanks to the smaller diameters of their nanotube pores, membranes fabricated with vertically aligned nanotubes grown on the stable layers display improved ion selectivity.

Directed Assembly of Hybrid Nanomaterials and Nanocomposites

Hybrid nanomaterials are molecular or colloidal-level combinations of organic and inorganic materials, or otherwise strongly dissimilar materials. They are often, though not exclusively, anisotropic in shape. A canonical example is an inorganic nanorod or nanosheet sheathed in, or decorated by, a polymeric or other organic material, where both the inorganic and organic components are important for the properties of the system. Hybrid nanomaterials and nanocomposites have generated strong interest for a broad range of applications due to their functional properties. Generating macroscopic assemblies of hybrid nanomaterials and nanomaterials in nanocomposites with controlled orientation and placement by directed assembly is important for realizing such applications. Here, a survey of critical issues and themes in directed assembly of hybrid nanomaterials and nanocomposites is provided, highlighting recent efforts in this field with particular emphasis on scalable methods.

Understanding Fast and Robust Thermo-osmotic Flows through Carbon Nanotube Membranes: Thermodynamics Meets Hydrodynamics

Following our recent theoretical prediction of the giant thermo-osmotic response of the water-graphene interface, we explore the practical implementation of waste heat harvesting with carbon-based membranes, focusing on model membranes of carbon nanotubes (CNT). To that aim, we combine molecular dynamics simulations and an analytical model considering the details of hydrodynamics in the membrane and at the tube entrances. The analytical model and the simulation results match quantitatively, highlighting the need to take into account both thermodynamics and hydrodynamics to predict thermo-osmotic flows through membranes. We show that, despite viscous entrance effects and a thermal short-circuit mechanism, CNT membranes can generate very fast thermo-osmotic flows, which can overcome the osmotic pressure of seawater. We then show that in small tubes confinement has a complex effect on the flow and can even reverse the flow direction. Beyond CNT membranes, our analytical model can guide the search for other membranes to generate fast and robust thermo-osmotic flows.

Catalytic CVD synthesis of boron nitride and carbon nanomaterials - synergies between experiment and theory

Low-dimensional carbon and boron nitride nanomaterials - hexagonal boron nitride, graphene, boron nitride nanotubes and carbon nanotubes - remain at the forefront of advanced materials research. Catalytic chemical vapour deposition has become an invaluable technique for reliably and cost-effectively synthesising these materials. In this review, we will emphasise how a synergy between experimental and theoretical methods has enhanced the understanding and optimisation of this synthetic technique. This review examines recent advances in the application of CVD to synthesising boron nitride and carbon nanomaterials and highlights where, in many cases, molecular simulations and quantum chemistry have provided key insights complementary to experimental investigation. This synergy is particularly prominent in the field of carbon nanotube and graphene CVD synthesis, and we propose here it will be the key to future advances in optimisation of CVD synthesis of boron nitride nanomaterials, boron nitride - carbon composite materials, and other nanomaterials generally.

A Forest of Sub-1.5-nm-wide Single-Walled Carbon Nanotubes over an Engineered Alumina Support

A precise control of the dimension of carbon nanotubes (CNTs) in their vertical array could enable many promising applications in various fields. Here, we demonstrate the growth of vertically aligned, single-walled CNTs (VA-SWCNTs) with diameters in the sub-1.5-nm range (0.98 ± 0.24 nm), by engineering a catalyst support layer of alumina via thermal annealing followed by ion beam treatment. We find out that the ion beam bombardment on the alumina allows the growth of ultra-narrow nanotubes, whereas the thermal annealing promotes the vertical alignment at the expense of enlarged diameters; in an optimal combination, these two effects can cooperate to produce the ultra-narrow VA-SWCNTs. According to micro- and spectroscopic characterizations, ion beam bombardment amorphizes the alumina surface to increase the porosity, defects, and oxygen-laden functional groups on it to inhibit Ostwald ripening of catalytic Fe nanoparticles effectively, while thermal annealing can densify bulk alumina to prevent subsurface diffusion of the catalyst particles. Our findings contribute to the current efforts of precise diameter control of VA-SWCNTs, essential for applications such as membranes and energy storage devices.

Oxygen-promoted catalyst sintering influences number density, alignment, and wall number of vertically aligned carbon nanotubes

A lack of synthetic control and reproducibility during vertically aligned carbon nanotube (CNT) synthesis has stifled many promising applications of organic nanomaterials. Oxygen-containing species are particularly precarious in that they have both beneficial and deleterious effects and are notoriously difficult to control. Here, we demonstrated diatomic oxygen's ability, independent of water, to tune oxide-supported catalyst thin film dewetting and influence nanoscale (diameter and wall number) and macro-scale (alignment and density) properties for as-grown vertically aligned CNTs. In particular, single- or few-walled CNT forests were achieved at very low oxygen loading, with single-to-multi-walled CNT diameters ranging from 4.8 ± 1.3 nm to 6.4 ± 1.1 nm over 0-800 ppm O₂, and an expected variation in alignment, where both were related to the annealed catalyst morphology. Morphological differences were not the result of subsurface diffusion, but instead occurred via Ostwald ripening under several hundred ppm O₂, and this effect was mitigated by high H₂ concentrations and not due to water vapor (as confirmed in O₂-free water addition experiments), supporting the importance of O₂ specifically. Further characterization of the interface between the Fe catalyst and Al₂O₃ support revealed that either oxygen-deficit metal oxide or oxygen-adsorption on metals could be functional mechanisms for the observed catalyst nanoparticle evolution. Taken as a whole, our results suggest that the impacts of O₂ and H₂ on the catalyst evolution have been underappreciated and underleveraged in CNT synthesis, and these could present a route toward facile manipulation of CNT forest morphology through control of the reactive gaseous atmosphere alone.

Real-Time Imaging of Self-Organization and Mechanical Competition in Carbon Nanotube Forest Growth

The properties of carbon nanotube (CNT) networks and analogous materials comprising filamentary nanostructures are governed by the intrinsic filament properties and their hierarchical organization and interconnection. As a result, direct knowledge of the collective dynamics of CNT synthesis and self-organization is essential to engineering improved CNT materials for applications such as membranes and thermal interfaces. Here, we use real-time environmental transmission electron microscopy (E-TEM) to observe nucleation and self-organization of CNTs into vertically aligned forests. Upon introduction of the carbon source, we observe a large scatter in the onset of nucleation of individual CNTs and the ensuing growth rates. Experiments performed at different temperatures and catalyst particle densities show the critical role of CNT density on the dynamics of self-organization; low-density CNT nucleation results in the CNTs becoming pinned to the substrate and forming random networks, whereas higher density CNT nucleation results in self-organization of the CNTs into bundles that are oriented perpendicular to the substrate. We also find that mechanical coupling between growing CNTs alters their growth trajectory and shape, causing significant deformations, buckling, and defects in the CNT walls. Therefore, it appears that CNT-CNT coupling not only is critical for self-organization but also directly influences CNT quality and likely the resulting properties of the forest. Our findings show that control of the time-distributed kinetics of CNT nucleation and bundle formation are critical to manufacturing well-organized CNT assemblies and that E-TEM can be a powerful tool to investigate the mesoscale dynamics of CNT networks.

Failure mechanism of the polymer infiltration of carbon nanotube forests

Polymer melt infiltration is one of the feasible methods for manufacturing filter membranes out of carbon nanotubes (CNTs) on large scales. Practically, however, its process suffers from low yields, and the mechanism behind this failure is rather poorly understood. Here, we investigate a failure mechanism of polymer melt infiltration of vertical aligned (VA-) CNTs. In penetrating the VA-CNT interstices, polymer melts exert a capillarity-induced attractive force laterally on CNTs at the moving meniscus, leading to locally agglomerated macroscale bunches. Such a large configurational change can deform and distort individual CNTs so much as to cause buckling or breakdown of the alignment. In view of membrane manufacturing, this irreversible distortion of nanotubes is detrimental, as it could block the transport path of the membranes. The failure mechanism of the polymer melt infiltration is largely attributed to steric hindrance and an energy penalty of confined polymer chains. Euler beam theory and scaling analysis affirm that CNTs with low aspect ratio, thick walls and sparse distribution can maintain their vertical alignment. Our results can enrich a mechanistic understanding of the polymer melt infiltration process and offer guidelines to the facile large-scale manufacturing of the CNT-polymer filter membranes.

Electrically Conductive Hierarchical Carbon Nanotube Networks with Tunable Mechanical Response

Small diameter carbon nanotube (CNTs) are synthesized directly from a parent CNT forest using a floating catalyst chemical vapor deposition (CVD) method. To support a new CNT generation from an existing forest, an alumina coating was applied to the CNT forest using atomic layer deposition (ALD). The new generation of small diameter CNTs (8 nm average) surround the first generation, filling the interstitial regions. The hierarchical forests exhibit a 5-10-fold increase in stiffness, and the two generations are electrically addressable in spite of the interfacial alumina layer between them. This work enables the design of complex CNT architectures with hierarchical features that bring tailored properties such as high specific surface area and robust mechanical properties that can benefit a range of applications.

Conjugated polyelectrolyte nano field emission adlayers

Here we report on a straightforward and rapid means of enhancing the field electron emission performance of nascent vertically aligned multi-walled carbon nanotubes by introducing a polar zwitterionic conjugated polyelectrolyte adlayer at the vacuum-emitter interface. We attribute the observed 66% decrease in turn-on electric field to the augmented emitter micro-morphology and shifted surface band structure. The composite emitters can be optically modulated by exploiting the absorption cross-section of the solution cast adlayer, which increases the local carrier concentration which broadens the effective electrostatic shape of the emitter during optical excitation. Assessment via scanning anode field emission microscopy reveals a 25% improvement in DC time stability, a significant reduction in long-term hysteresis shift, and a threefold increase in bandwidth during pulsed mode operation.

Enhanced ionic liquid mobility induced by confinement in 1D CNT membranes

Water confined within carbon nanotubes (CNT) exhibits tremendous enhanced transport properties. Here, we extend this result to ionic liquids (IL) confined in vertically aligned CNT membranes. Under confinement, the IL self-diffusion coefficient is increased by a factor 3 compared to its bulk reference. This could lead to high power battery separators.

A sweet spot for highly efficient growth of vertically aligned single-walled carbon nanotube forests enabling their unique structures and properties

We investigated the correlation between growth efficiency and structural parameters of single-walled carbon nanotube (SWCNT) forests and report the existence of a SWCNT "sweet spot" in the CNT diameter and spacing domain for highly efficient synthesis. Only within this region could SWCNTs be grown efficiently. Through the investigation of the growth rates for ∼340 CNT forests spanning diameters from 1.3 to 8.0 nm and average spacing from 5 to 80 nm, this "sweet spot" was found to exist because highly efficient growth was constrained by several mechanistic boundaries that either hindered the formation or reduced the growth rate of SWCNT forests. Specifically, with increased diameter SWCNTs transitioned to multiwalled CNTs (multiwall border), small diameter SWCNTs could only be grown at low growth rates (low efficiency border), sparse SWCNTs lacked the requirements to vertically align (lateral growth border), and high density catalysts could not be prepared (high catalyst density border). As a result, the SWCNTs synthesized within this "sweet spot" possessed a unique set of characteristics vital for the development applications, such as large diameter, long, aligned, defective, and high specific surface area.

Advanced catalyst design induced enhancement of multi-walled nanotube debundling and electrical conductivity of multi-walled nanotube/silicone composites

Density of MWNT bundles can be controlled by synthetic process of metal catalysts. Direct correlation between morphology of MWNT catalysts and electrical conductivity of MWNT/polymer composite was experimentally demonstrated.

Efficient Transfer Doping of Carbon Nanotube Forests by MoO3

We dope nanotube forests using evaporated MoO3 and observe the forest resistivity to decrease by 2 orders of magnitude, reaching values as low as ∼5 × 10(-5) Ωcm, thus approaching that of copper. Using in situ photoemission spectroscopy, we determine the minimum necessary MoO3 thickness to dope a forest and study the underlying doping mechanism. Homogenous coating and tube compaction emerge as key factors for decreasing the forest resistivity. When all nanotubes are fully coated with MoO3 and packed, conduction channels are created both inside the nanotubes and on the outside oxide layer. This is supported by density functional theory calculations, which show a shift of the Fermi energy of the nanotubes and the conversion of the oxide into a layer of metallic character. MoO3 doping removes the need for chirality control during nanotube growth and represents a step forward toward the use of forests in next-generation electronics and in power cables or conductive polymers.

Low-Temperature Growth of Carbon Nanotube Forests Consisting of Tubes with Narrow Inner Spacing Using Co/Al/Mo Catalyst on Conductive Supports

We grow dense carbon nanotube forests at 450 °C on Cu support using Co/Al/Mo multilayer catalyst. As a partial barrier layer for the diffusion of Co into Mo, we apply very thin Al layer with the nominal thickness of 0.50 nm between Co and Mo. This Al layer plays an important role in the growth of dense CNT forests, partially preventing the Co-Mo interaction. The forests have an average height of ∼300 nm and a mass density of 1.2 g cm(-3) with tubes exhibiting extremely narrow inner spacing. An ohmic behavior is confirmed between the forest and Cu support with the lowest resistance of ∼8 kΩ. The forest shows a high thermal effusivity of 1840 J s(-0.5) m(-2) K(-1), and a thermal conductivity of 4.0 J s(-1) m(-1) K(-1), suggesting that these forests are useful for heat dissipation devices.

Fast Water Thermo-pumping Flow Across Nanotube Membranes for Desalination

Development of high-efficiency and low-cost seawater desalination technologies is critical to meet global water crisis. Here we report a fast water pumping method in which the water molecules in seawater are continuously pumped across nanotube membranes driven by a small temperature difference, opening the possibility of high-throughput small-scale desalination devices driven by low-grade thermal energy. Using molecular dynamics simulations, we show that an equivalent driving pressure of 5.3 MPa is achieved with a temperature difference of only 15 K. The remarkable water pumping ability is attributed to the asymmetric thermal fluctuation of water molecules. With this method, a 10 cm(2) nanotube membrane with 1.5 × 10(13) pores per cm(2) will produce freshwater with a flow rate of 7.77 L/h under a small temperature difference of 15 K.

Influence of packing density and surface roughness of vertically-aligned carbon nanotubes on adhesive properties of gecko-inspired mimetics

We have systematically studied the macroscopic adhesive properties of vertically aligned nanotube arrays with various packing density and roughness. Using a tensile setup in shear and normal adhesion, we find that there exists a maximum packing density for nanotube arrays to have adhesive properties. Too highly packed tubes do not offer intertube space for tube bending and side-wall contact to surfaces, thus exhibiting no adhesive properties. Likewise, we also show that the surface roughness of the arrays strongly influences the adhesion properties and the reusability of the tubes. Increasing the surface roughness of the array strengthens the adhesion in the normal direction, but weakens it in the shear direction. Altogether, these results allow progress toward mimicking the gecko's vertical mobility.

Active vacuum brazing of CNT films to metal substrates for superior electron field emission performance

The joining of macroscopic films of vertically aligned multiwalled carbon nanotubes (CNTs) to titanium substrates is demonstrated by active vacuum brazing at 820 °C with a Ag-Cu-Ti alloy and at 880 °C with a Cu-Sn-Ti-Zr alloy. The brazing methodology was elaborated in order to enable the production of highly electrically and thermally conductive CNT/metal substrate contacts. The interfacial electrical resistances of the joints were measured to be as low as 0.35 Ω. The improved interfacial transport properties in the brazed films lead to superior electron field-emission properties when compared to the as-grown films. An emission current of 150 μA was drawn from the brazed nanotubes at an applied electric field of 0.6 V μm-1. The improvement in electron field-emission is mainly attributed to the reduction of the contact resistance between the nanotubes and the substrate. The joints have high re-melting temperatures up to the solidus temperatures of the alloys; far greater than what is achievable with standard solders, thus expanding the application potential of CNT films to high-current and high-power applications where substantial frictional or resistive heating is expected.

Controlling the Diameter of Single-Walled Carbon Nanotubes by Improving the Dispersion of the Uniform Catalyst Nanoparticles on Substrate

To have uniform nanoparticles individually dispersed on substrate before single-walled carbon nanotubes (SWNTs) growth at high temperature is the key for controlling the diameter of the SWNTs. In this letter, a facile approach to control the diameter and distribution of the SWNTs by improving the dispersion of the uniform Fe/Mo nanoparticles on silicon wafers with silica layer chemically modified by 1,1,1,3,3,3-hexamethyldisilazane under different conditions is reported. It is found that the dispersion of the catalyst nanoparticles on Si wafer surface can be improved greatly from hydrophilic to hydrophobic, and the diameter and distribution of the SWNTs depend strongly on the dispersion of the catalyst on the substrate surface. Well dispersion of the catalyst results in relatively smaller diameter and narrower distribution of the SWNTs due to the decrease of aggregation and enhancement of dispersion of the catalyst nanoparticles before growth. It is also found that the diameter of the superlong aligned SWNTs is smaller with more narrow distribution than that of random nanotubes.

Synthesis of high purity chain-like carbon nanospheres in ultrahigh yield, and their microwave absorption properties

In the article, we report a simple approach for the mass production of chain-like CNSs over Fe/SnO₂ nanoparticles. And ultrahigh yields (309) of CNCs were reported, and the as-synthesized chain-like CNSs exhibit good microwave absorbing ability.

Water-assisted growth of uniform 100 mm diameter SWCNT arrays

We report a simple method for growing high-quality single-walled carbon nanotube (SWCNT) arrays on 100 mm wafers via the addition of water vapor to highly purified gases during the CNT growth step. We show that adding a small amount of water during growth helps to create a uniform catalyst distribution and yields high-quality (Raman G/D of 26 ± 3), high-density (up to 6 × 10(11) cm(-2)) and uniform SWCNT arrays on 100 mm large wafers. We rationalize our finding by suggesting that the addition of water decreases catalyst mobility, preventing its coarsening at higher temperatures. We also report a new mechanism of catalyst inactivation in wafer-scale growth using ultrapurified gas sources by the formation of large, 5 ± 3 μm iron particles. We found such formations to be common for substrates with large temperature gradients, such as for wafers processed in a typical cold-wall chemical vapor deposition reactor.

Dry-processable carbon nanotubes for functional devices and composites

Assembly of carbon nanotubes (CNTs) in effective and productive ways is of vital importance to their application. Recent progress in synthesis of CNTs has inspired new strategies for utilizing the unique physiochemical properties of CNTs in macroscale materials and devices. Assembling CNTs by dry processes (e.g., directly collecting CNTs in the form of freestanding films followed by pressing, stretching, and multilayer stacking instead of dispersing them in solution) not only considerably simplifies the processes but also avoids structural damage to the CNTs. Various dry-processable CNTs are reviewed, focusing on their synthesis, properties, and applications. The synthesis techniques are organized in terms of aggregative morphologies and microstructure control of CNTs. Important applications such as functional thin-film devices, strong CNT films, and composites are included. The opportunities and challenges in the synthesis techniques and fabrication of advanced composites and devices are discussed.

Growth kinetics and growth mechanism of ultrahigh mass density carbon nanotube forests on conductive Ti/Cu supports

We evaluate the growth kinetics and growth mechanism of ultrahigh mass density carbon nanotube forests. They are synthesized by chemical vapor deposition at 450 °C using a conductive Ti/Cu support and Co-Mo catalyst system. We find that Mo stabilizes Co particles preventing lift off during the initial growth stage, thus promoting the growth of ultrahigh mass density nanotube forests by the base growth mechanism. The morphology of the forest gradually changes with growth time, mostly because of a structural change of the catalyst particles. After 100 min growth, toward the bottom of the forest, the area density decreases from ∼ 3-6 × 10(11) cm(-2) to ∼ 5 × 10(10) cm(-2) and the mass density decreases from 1.6 to 0.38 g cm(-3). We also observe part of catalyst particles detached and embedded within nanotubes. The progressive detachment of catalyst particles results in the depletion of the catalyst metals on the substrate surfaces. This is one of the crucial reasons for growth termination and may apply to other catalyst systems where the same features are observed. Using the packed forest morphology, we demonstrate patterned forest growth with a pitch of ∼ 300 nm and a line width of ∼ 150 nm. This is one of the smallest patterning of the carbon nanotube forests to date.

Ultra-high-aspect-orthogonal and tunable three dimensional polymeric nanochannel stack array for BioMEMS applications

Nanofabrication technologies have been a strong advocator for new scientific fundamentals that have never been described by traditional theory, and have played a seed role in ground-breaking nano-engineering applications. In this study, we fabricated ultra-high-aspect (∼10(6) with O(100) nm nanochannel opening and O(100) mm length) orthogonal nanochannel array using only polymeric materials. Vertically aligned nanochannel arrays in parallel can be stacked to form a dense nano-structure. Due to the flexibility and stretchability of the material, one can tune the size and shape of the nanochannel using elongation and even roll the stack array to form a radial-uniformly distributed nanochannel array. The roll can be cut at discretionary lengths for incorporation with a micro/nanofluidic device. As examples, we demonstrated ion concentration polarization with the device for Ohmic-limiting/overlimiting current-voltage characteristics and preconcentrated charged species. The density of the nanochannel array was lower than conventional nanoporous membranes, such as anodic aluminum oxide membranes (AAO). However, accurate controllability over the nanochannel array dimensions enabled multiplexed one microstructure-on-one nanostructure interfacing for valuable biological/biomedical microelectromechanical system (BioMEMS) platforms, such as nano-electroporation.

Bio-inspired hierarchical polymer fiber-carbon nanotube adhesives

Hierarchical pillar arrays consisting of micrometer-sized polymer setae covered by carbon nanotubes are engineered to deliver the role of spatulae, mimicking the fibrillar adhesive surfaces of geckos. These biomimetic structures conform well and achieve better attachment to rough surfaces, providing a new platform for a variety of applications.

En route to controlled catalytic CVD synthesis of densely packed and vertically aligned nitrogen-doped carbon nanotube arrays

The catalytic chemical vapour deposition (c-CVD) technique was applied in the synthesis of vertically aligned arrays of nitrogen-doped carbon nanotubes (N-CNTs). A mixture of toluene (main carbon source), pyrazine (1,4-diazine, nitrogen source) and ferrocene (catalyst precursor) was used as the injection feedstock. To optimize conditions for growing the most dense and aligned N-CNT arrays, we investigated the influence of key parameters, i.e., growth temperature (660, 760 and 860 °C), composition of the feedstock and time of growth, on morphology and properties of N-CNTs. The presence of nitrogen species in the hot zone of the quartz reactor decreased the growth rate of N-CNTs down to about one twentieth compared to the growth rate of multi-wall CNTs (MWCNTs). As revealed by electron microscopy studies (SEM, TEM), the individual N-CNTs (half as thick as MWCNTs) grown under the optimal conditions were characterized by a superior straightness of the outer walls, which translated into a high alignment of dense nanotube arrays, i.e., 5 × 10(8) nanotubes per mm(2) (100 times more than for MWCNTs grown in the absence of nitrogen precursor). In turn, the internal crystallographic order of the N-CNTs was found to be of a 'bamboo'-like or 'membrane'-like (multi-compartmental structure) morphology. The nitrogen content in the nanotube products, which ranged from 0.0 to 3.0 wt %, was controlled through the concentration of pyrazine in the feedstock. Moreover, as revealed by Raman/FT-IR spectroscopy, the incorporation of nitrogen atoms into the nanotube walls was found to be proportional to the number of deviations from the sp(2)-hybridisation of graphene C-atoms. As studied by XRD, the temperature and the [pyrazine]/[ferrocene] ratio in the feedstock affected the composition of the catalyst particles, and hence changed the growth mechanism of individual N-CNTs into a 'mixed base-and-tip' (primarily of the base-type) type as compared to the purely 'base'-type for undoped MWCNTs.