Continuous electrodeposition for lightweight, highly conducting and strong carbon nanotube-copper composite fibers

Ultrastretchable Helical Carbon Nanotube-Woven Film

Helical carbon nanotube (HCNT) is regarded as one of the most promising nanomaterials due to its excellent tensile strength and superhigh stretchability. Here, a novel HCNT-woven film (HWF) is proposed, and its in-plane and out-of-plane mechanical properties are systematically investigated via molecular dynamics (MD) simulation. The MD results show that HWF possesses highly stretchable capability resulting from sliding and straightening of CNT segments, and the maximum tensile strain can reach 2113%. Furthermore, the HWF presents an obvious tensile mechanical anisotropy. The torsion failure is the main fracture mode when the HWF is stretched along the longitudinal direction. However, when the HWF is stretched along the transverse direction, the fracture is mainly caused by intertube compression. On the other hand, the HWF can dissipate large amount of kinetic energy of projectile via sliding and fracture of HCNTs, leading to high specific penetration energy. This work provides a theoretical guidance for designing and fabricating next-generation superstrong two-dimensional CNT-based nanomaterials.

Enhancing the Interaction of Carbon Nanotubes by Metal-Organic Decomposition with Improved Mechanical Strength and Ultra-Broadband EMI Shielding Performance

The remarkable properties of carbon nanotubes (CNTs) have led to promising applications in the field of electromagnetic interference (EMI) shielding. However, for macroscopic CNT assemblies, such as CNT film, achieving high electrical and mechanical properties remains challenging, which heavily depends on the tube-tube interactions of CNTs. Herein, we develop a novel strategy based on metal-organic decomposition (MOD) to fabricate a flexible silver-carbon nanotube (Ag-CNT) film. The Ag particles are introduced in situ into the CNT film through annealing of MOD, leading to enhanced tube-tube interactions. As a result, the electrical conductivity of Ag-CNT film is up to 6.82 × 105 S m-1, and the EMI shielding effectiveness of Ag-CNT film with a thickness of ~ 7.8 μm exceeds 66 dB in the ultra-broad frequency range (3-40 GHz). The tensile strength and Young's modulus of Ag-CNT film increase from 30.09 ± 3.14 to 76.06 ± 6.20 MPa (~ 253%) and from 1.12 ± 0.33 to 8.90 ± 0.97 GPa (~ 795%), respectively. Moreover, the Ag-CNT film exhibits excellent near-field shielding performance, which can effectively block wireless transmission. This innovative approach provides an effective route to further apply macroscopic CNT assemblies to future portable and wearable electronic devices.

High-Strength Carbon Nanotube Fibers from Purity Control by Atomized Catalytic Pyrolysis and Alignment Improvement by Continuous Large Prestraining

Transferring the high strength of individual carbon nanotubes (CNTs) to macroscopic fibers is still a major technical challenge. In this study, CNT fibers are wound from a hollow cylindrical assembly. In particular, atomized catalytic pyrolysis is utilized to produce the fiber and control its purity. The pristine fiber is then continuously prestrained to have a highly aligned structure for subsequent full densification. Experimental measurements show that the final fiber possesses a high tensile strength (8.0 GPa), specific strength (5.54 N tex-1 (tex: the weight (g) of a fiber of 1 km long)), Young's modulus (350 GPa), and elongation at break (4%). Such an excellent combination is superior to that of any other existing fiber and attributed to the efficient stress transfer among the highly aligned and packed CNTs. Our study provides a new strategy involving atomized catalysis for developing superstrong CNT assemblies such as fibers and films for practical applications.

Single-Walled Carbon Nanotube/Copper Core-Shell Fibers with a High Specific Electrical Conductivity

Carbon nanotube (CNT)/Cu core-shell fibers are a promising material for lightweight conductors due to their higher conductivity than pure CNT fibers and lower density than traditional Cu wires. However, the electrical properties of the hybrid fiber have been unsatisfactory, mainly because of the weak CNT-Cu interfacial interaction. Here we report the fabrication of a single-walled CNT (SWCNT)/Cu core-shell fiber that outperforms commercial Cu wires in terms of specific electrical conductivity and current carrying capacity. A dense and uniform Cu shell was coated on the surface of wet-spun SWCNT fibers using a combination of magnetron sputtering and electrochemical deposition. Our SWCNT/Cu core-shell fibers had an ultrahigh specific electrical conductivity of (1.01 ± 0.04) × 10⁴ S m² kg^-1, 56% higher than Cu. Experimental and simulation results show that oxygen-containing functional groups on the surface of a wet-spun SWCNT fiber interact with the sputtered Cu atoms to produce strong bonding. Our hybrid fiber preserved its integrity and conductivity well after more than 5000 bending cycles. Furthermore, the current carrying capacity of the coaxial fiber reached 3.14 × 10⁵ A cm^-2, three times that of commercial Cu wires.

Structure and Physical Properties of Conductive Bamboo Fiber Bundle Fabricated by Magnetron Sputtering

The variety of conductive fibers has been constantly enriched in recent years, and it has made rapid development in the fields of electronic textiles, intelligent wearable, and medical care. However, the environmental damage caused by the use of large quantities of synthetic fibers cannot be ignored, and there is little research on conductive fibers in the field of bamboo, a green and sustainable material. In this work, we used the alkaline sodium sulfite method to remove lignin from bamboo, prepared a conductive bamboo fiber bundle by coating a copper film on single bamboo fiber bundles using DC magnetron sputtering, and analyzed its structure and physical properties under different process parameters, finding the most suitable preparation condition that combines cost and performance. The results of the scanning electron microscope show that the coverage of copper film can be improved by increasing the sputtering power and prolonging the sputtering time. The resistivity of the conductive bamboo fiber bundle decreased with the increase of the sputtering power and sputtering time, up to 0.22 Ω·mm; at the same time, the tensile strength of the conductive bamboo fiber bundle continuously decreased to 375.6 MPa. According to the X-ray diffraction results, Cu in the copper film on the surface of the conductive bamboo fiber bundle shows the preferred orientation of (111) the crystal plane, indicating that the prepared Cu film has high crystallinity and good film quality. X-ray photoelectron spectroscopy results show that Cu in the copper film exists in the form of Cu⁰ and Cu²⁺, and most are Cu⁰. Overall, the development of the conductive bamboo fiber bundle provides a research basis for the development of conductive fibers in a natural renewable direction.

Ultrastrong Carbon Nanotubes-Copper Core-Shell Wires with Enhanced Electrical and Thermal Conductivities as High-Performance Power Transmission Cables

Demands for high-performance electrical power transmission cables continue to rise, especially for offshore power transmission, electric vehicles, portable electronics, and deployable military applications. Carbon nanotubes (CNTs)-Copper (Cu) core-shell wire is regarded as one of the best candidate material systems for transmitting electricity and thermal energy. In this study, a facile and robust approach was developed to enhance the CNT-Cu interfacial interactions. This approach consists of a substrate-enhanced electroless deposition step for Cu pre-seeding and thiol functionalization. Benefiting from the thiol-activated CNT surface and Cu seed deposit, the CNTs-Cu core-shell wire forms a densely packed Cu shell with a void-free CNT-Cu interface. Consequently, the CNTs-Cu core-shell wire possesses (1) superior specific strength (eightfold stronger), (2) 30% higher specific conductivity, (3) 120% higher specific ampacity, and (4) an impressive 110% higher thermal conductivity compared with pure Cu wires. Moreover, this composite wire still maintains its structural integrity and electrical properties over 600 cycles of the fatigue bending test, rendering this system an excellent candidate for high-performance electrical cable and conductor applications.

Continuously processing waste lignin into high-value carbon nanotube fibers

High value utilization of renewable biomass materials is of great significance to the sustainable development of human beings. For example, because biomass contains large amounts of carbon, they are ideal candidates for the preparation of carbon nanotube fibers. However, continuous preparation of such fibers using biomass as carbon source remains a huge challenge due to the complex chemical structure of the precursors. Here, we realize continuous preparation of high-performance carbon nanotube fibers from lignin by solvent dispersion, high-temperature pyrolysis, catalytic synthesis, and assembly. The fibers exhibit a tensile strength of 1.33 GPa and an electrical conductivity of 1.19 × 10⁵S m^-1, superior to that of most biomass-derived carbon materials to date. More importantly, we achieve continuous production rate of 120 m h^-1. Our preparation method is extendable to other biomass materials and will greatly promote the high value application of biomass in a wide range of fields.

Review of Recent Development in Copper/Carbon Composites Prepared by Infiltration Technique

The liquid metal infiltration of carbon preformed with copper and its alloys is already an established and well-known process. It is extensively used by the electronic industry to produce heat sinks of power electronics and electric contacts and sliding electric contacts. The advantage of the process is its ability to produce near net shape components with high volume fractions of carbon at a relatively low price. The process is carried out in a vacuum and with low applied pressure. However, a strong dependence on the temperature of infiltration and its precise control is significant for the sound final product. For certain pair carbon matrix–copper alloys, different results could be obtained according to the infiltration temperature. If the temperature is too low, the solidification may occur prior to complete infiltration (high final porosity). When the temperature is too high, undesirable reactions may occur at the fiber–matrix interface (e.g., corrosive carbides). Therefore, there are still a lot of scientific papers pushing this technology to new directions and over old limits. Publications inside scientific journals within this field deal with composite materials for sliding electrical contact and electrical contact materials, sealing materials, parts of brake disks, pantograph strips for high-speed railways, other electric and mechanical applications and even for wall surface shields in future fusion devices. The present paper reviews used carbon preforms, copper alloys, technological parameters, properties of prepared composites prepared via infiltration during the last 12 years. It can be stated that 1/3 of the papers were published within the last 3 years. Moreover, renewed interest in this low-cost technique could be expected within the next few years due to climate programs and increasing prices of the energy resources.

Fabrication of high-performance carbon nanotube/copper composite fibers by interface thiol-modification

Carbon nanotube (CNT)/copper (Cu) composite fibers are placed great expectations as the next generation of light-weight, conductive wires. However, the electrical and mechanical performances still need to be enhanced. Herein, we demonstrate a strategy that is electrodeposition Cu on thiolated CNT fibers to solve the grand challenge which is enhancing the performance of CNT/Cu composite fibers. Thiol groups are introduced to the surface of the CNT fibers through a controllable O₂plasma carboxylation process and amide reaction. Compared with CNT/Cu composite fibers, there are 82.7% and 29.6% improvements in electrical conductivity and tensile strength of interface thiol-modification composite fibers. The enhancement mechanism is also explored that thiolated CNT fibers could make strong interactions between Cu and CNT, enhancing the electrical and mechanical performance of CNT/Cu composites. This work proposes a convenient, heat-treatment-free strategy for high-performance CNT/Cu composite fibers, which can be manufactured for large-scale production and applied to next-generation conductive wires.

An Axially Continuous Graphene-Copper Wire for High-Power Transmission: Thermoelectrical Characterization and Mechanisms

The demand for high-power electrical transmission continues to increase with technical advances in electric vehicles, unmanned drones, portable devices, and deployable military applications. In this study, significantly enhanced electrical properties (i.e., a 450% increase in the current density breakdown limit) are demonstrated by synthesizing axially continuous graphene layers on microscale-diameter wires. To elucidate the underlying mechanisms of the observed enhancements, the electrical properties of pure copper wires and axially continuous graphene-copper (ACGC) wires with three different diameters are characterized while controlling the experimental conditions, including ambient temperature, gases, and pressure. The study reveals that the main mechanism that allows the application of extremely large current densities (>400 000 A cm^-2 ) through the ACGC wires is threefold: the continuous graphene layers considerably improve: 1) surface heat dissipation (224% higher), 2) electrical conductivity (41% higher), and 3) thermal stability (41.2% lower resistivity after thermal cycles up to 450 °C), compared with pure copper wires. In addition, it is observed, through the use of high-speed camera images, that the ACGC wires exhibit very different failure behavior near the current density limit, compared with the pure copper wires.

Fabrication of Metal/Carbon Nanotube Composites by Electrochemical Deposition

Metal/carbon nanotube (CNT) composites are promising functional materials due to the various superior properties of CNTs in addition to the characteristics of metals, and consequently, many fabrication processes of these composites have been vigorously researched. In this paper, the fabrication process of metal/CNT composites by electrochemical deposition, including electrodeposition and electroless deposition, are comprehensively reviewed. A general introduction for fabrication of metal/CNT composites using the electrochemical deposition is carried out. The fabrication methods can be classified into three types: (1) composite plating by electrodeposition or electroless deposition, (2) metal coating on CNT by electroless deposition, and (3) electrodeposition using CNT templates, such as CNT sheets and CNT yarns. The performances of each type have been compared and explained especially from the view point of preparation methods. In the cases of (1) composite plating and (2) metal coating on CNTs, homogeneous dispersion of CNTs in electrochemical deposition baths is essential for the formation of metal/CNT composites with homogeneous distribution of CNTs, which leads to high performance composites. In the case of (3) electrodeposition using CNT templates, the electrodeposition of metals not only on the surfaces but also interior of the CNT templates is the key process to fabricate high performance metal/CNT composites.

Application-Driven Carbon Nanotube Functional Materials

Carbon nanotube functional materials (CNTFMs) represent an important research field in transforming nanoscience and nanotechnology into practical applications, with potential impact in a wide realm of science, technology, and engineering. In this review, we combine the state-of-the-art research activities of CNTFMs with the application prospect, to highlight critical issues and identify future challenges. We focus on macroscopic long fibers, thin films, and bulk sponges which are typical CNTFMs in different dimensions with distinct characteristics, and also cover a variety of derived composite/hierarchical materials. Critical issues related to their structures, properties, and applications as robust conductive skeletons or high-performance flexible electrodes in mechanical and electronic devices, advanced energy conversion and storage systems, and environmental areas have been discussed specifically. Finally, possible solutions and directions are proposed for overcoming current obstacles and promoting future efforts in the field.

A Straightforward Approach to Create Ag/SWCNT Composites

Flexible and conductive materials have a high application potential across many parts of modern life. In this work, thin free-standing films from single-walled carbon nanotubes (SWCNTs) were doped with Ag to enhance their electrical conductivity. A facile method to integrate these two materials is described herein. As a consequence, the material exhibited a six-fold boost to the electrical conductivity: an increase from 250 ± 11 S/cm to 1721 ± 125 S/cm. Interestingly, the specific conductivity remained at a comparable level upon doping, so the material was deemed promising in exploitation fields whereweight is of the essence. Furthermore, the material showed good bending characteristics, thereby revealing its applicability in flexible electronics.

Nanocatalysts in electrosynthesis

Electrosynthesis is to use electricity to drive chemical reactions for chemical synthesis and is potentially a green approach to fuel and energy sustainability. Nanostructured catalysts play an important role in promoting electrochemical reactions under green chemistry conditions. This perspective first provides a brief tutorial on electrosynthesis and the roles the nanocatalysts play in the synthesis. It then outlines the common strategies used to develop nanocatalysts for hydrogen evolution reaction, CO2 reduction reaction, and biomass upgrading. The perspective further summarizes the current methodologies that have been developed for scaling-up synthesis of nanocatalysts, which will be essential for the electrosynthesis to become a viable industry approach.

Critical challenges and advances in the carbon nanotube-metal interface for next-generation electronics

Next-generation electronics can no longer solely rely on conventional materials; miniaturization of portable electronics is pushing Si-based semiconductors and metallic conductors to their operational limits, flexible displays will make common conductive metal oxide materials obsolete, and weight reduction requirement in the aerospace industry demands scientists to seek reliable low-density conductors. Excellent electrical and mechanical properties, coupled with low density, make carbon nanotubes (CNTs) attractive candidates for future electronics. However, translating these remarkable properties into commercial macroscale applications has been disappointing. To fully realize their great potential, CNTs need to be seamlessly incorporated into metallic structures or have to synergistically work alongside them which is still challenging. Here, we review the major challenges in CNT-metal systems that impede their application in electronic devices and highlight significant breakthroughs. A few key applications that can capitalize on CNT-metal structures are also discussed. We specifically focus on the interfacial interaction and materials science aspects of CNT-metal structures.

Aligned carbon nanotube fibers for fiber-shaped solar cells, supercapacitors and batteries

Aligned carbon nanotube (CNT) fibers have been considered as one of the ideal candidate electrodes for fiber-shaped energy harvesting and storage devices, due to their merits of flexibility, lightweight, desirable mechanical property, outstanding electrical conductivity as well as high specific surface area. Herein, the recent advancements on the aligned CNT fibers for energy harvesting and storage devices are reviewed. The synthesis, structure, and properties of aligned carbon nanotube fibers are briefly summarized. Then, their applications in fiber-shaped energy harvesting and storage devices (i.e., solar cells, supercapacitors, and batteries) are demonstrated. The remaining challenges are finally discussed to highlight the future research direction in the development of aligned CNT fibers for fiber-shaped energy devices.

One-step coating of Ni–Fe alloy outerwear on 1–3-dimensional nanomaterials by a novel technology

A simple one-step electrodeposition approach was developed to manufacture Ni–Fe alloy@1–3-dimensional core–shell nanomaterials using a novel technology.

On the resistivity, temperature coefficient of resistance, and ampacity of Cu–CNT and Ni–CNT composites

The annealing (at 1073 K under Ar) of Ni–CNT composite, featuring CNT being fully embedded in Ni, leads to a highly interconnected system (by Ni nodules) with a decreased resistivity, as opposed to Cu–CNT composite.

Remarkable Effects of an Electrodeposited Copper Skin on the Strength and the Electrical and Thermal Conductivities of Reduced Graphene Oxide-Printed Scaffolds

Architected Cu/reduced graphene oxide (rGO) heterostructures are achieved by electrodepositing copper on filament-printed rGO scaffolds. The Cu coating perfectly contours the printed rGO structure, but isolated Cu particles also permeate inside the filaments. Although the Cu deposition conveys a certain mass augment, the three-dimensional (3D) structures remain reasonably light (bulk density ≅ 0.42 g·cm^-3). The electrical conductivity (σ_e) of the Cu/rGO structure (∼8 × 10⁴ S·m^-1) shows a notable increment compared to σ_e of the rGO structure (∼2 × 10² S·m^-1). The effect on the scaffold robustness is also notable with an increase of the compressive strength by nearly 10 times (from 20 kPa of the rGO scaffold to 150 kPa of the Cu/rGO structure) and cyclability as well. The improved thermal conductivity of the Cu-coated scaffolds (∼4 times higher), in addition to the σ_e and strength improvements, suggests that 3D Cu/rGO structures could be suitable assemblies for integration into thermal dissipation systems, particularly as thermal interface materials, for compact electronic devices.

Dynamic Liquid Membrane Electrochemical Modification of Carbon Nanotube Fiber for Electrochemical Microfabrication

Carbon nanotube fibers (CNFs) are a promising material for use as lightweight, high-strength, electrically conducting tool cathodes in wire electrochemical micromachining (WECMM) in which a high-performance tool cathode is crucial for optimal processing performance. However, the outstanding advantages of pristine CNFs, such as fiber strength, electrical conductivity, and hydrophilic surface, have so far remained underutilized as tool cathodes in WECMM. Herein, electrochemical modification using a dynamic liquid membrane is proposed as an effective online method for functionalizing CNFs prior to WECMM. The proposed method not only improves the assembly accuracy and efficiency but also avoids unnecessary damage to the modified CNF during installation. The introduced functional groups (-OH and -COOH) effectively improved the electrical conductivity and hydrophilicity of CNFs. The influences of H₂O₂ concentration, applied voltage, and anodization time on the surface modification process were examined experimentally. The use of a pulsed voltage was further proposed to prevent the loss of fiber strength due to over-anodization. Finally, the use of modified CNF electrodes with good surface morphology, strength, and conductivity in WECMM was demonstrated to afford superior machining stability, efficiency, and accuracy as well as improved surface quality compared with the conventional tool cathodes.

Understanding the Mechanical and Conductive Properties of Carbon Nanotube Fibers for Smart Electronics

The development of fiber-based smart electronics has provoked increasing demand for high-performance and multifunctional fiber materials. Carbon nanotube (CNT) fibers, the 1D macroassembly of CNTs, have extensively been utilized to construct wearable electronics due to their unique integration of high porosity/surface area, desirable mechanical/physical properties, and extraordinary structural flexibility, as well as their novel corrosion/oxidation resistivity. To take full advantage of CNT fibers, it is essential to understand their mechanical and conductive properties. Herein, the recent progress regarding the intrinsic structure-property relationship of CNT fibers, as well as the strategies of enhancing their mechanical and conductive properties are briefly summarized, providing helpful guidance for scouting ideally structured CNT fibers for specific flexible electronic applications.

Ultrastrong and Stiff Carbon Nanotube/Aluminum-Copper Nanocomposite via Enhancing Friction between Carbon Nanotubes

Researchers have been aiming to replace copper with carbon nanotube/copper nanocomposites, which are lighter and exhibit better electrical, mechanical, and thermal properties. However, the strength is far below pure carbon nanotube assembly and even much lower than some copper-based alloys. This disadvantage hinders the extensive application of carbon nanotube/copper nanocomposites. In this study, the carbon nanotube/aluminum-copper nanocomposites with ultra-strength and stiffness were prepared. The strength and elasticity modulus of composite reached as high as 6.6 and 500 GPa, respectively, while a high conductivity of 1.8 × 10⁷ S/m was maintained. This can be attributed to the diffusion of Cu and Al atoms into the carbon nanotube fiber, which enhances friction between the carbon nanotubes by "pinning" and "bridging". This structure provides us with novel insights into the design of carbon nanotubes/metal nanocomposites with ultrahigh strength and conductivity.

Electroless Plating of Graphene Aerogel Fibers for Electrothermal and Electromagnetic Applications

Graphene aerogel fibers (GAFs) with low density, high specific surface area, and high porosity can be used as the host material to incorporate another component and thus form multifunctional fibers, which have potential applications in wearable devices, thermoregulating apparatus, sensors, and so forth. However, the intrinsically low electric conductivity of GAFs hampers them in the fields of electrothermal heating and electromagnetic interference (EMI) shielding. Herein, we report a new aerogel fiber composed by graphene sheets and nickel nanoparticles with low density (55-192 mg/cm³), high electric conductivity (0.8 × 10³ to 4.5 × 10⁴ S/m), and high specific surface area (49-105 m²/g). The graphene/Ni aerogel fibers (GNAFs) were synthesized initially from reduced graphene oxide hydrogel fibers followed by an electroless plating process. Further investigations have demonstrated that the resulting GNAFs possess excellent electrothermal property, faster electrothermal response, high mechanical and electrical stability as the electric wire, and excellent EMI shielding performance as the composite filler. The saturated temperature of GNAFs can reach 174 °C with an applied voltage of only 5 V, and the heating rate surpasses those of commercial Kanthal and Nichrome wires about 2.1 times and 2.6 times, respectively. The EMI shielding effectiveness of GNAFs is higher than 30 dB at the long bandwidth of 12.5-20 GHz. Specifically, it can shield more than 99.99% of the incident wave at the bandwidth of 15-20 GHz.

High Ampacity Carbon Nanotube Materials

Constant evolution of technology is leading to the improvement of electronical devices. Smaller, lighter, faster, are but a few of the properties that have been constantly improved, but these developments come hand in hand with negative downsides. In the case of miniaturization, this shortcoming is found in the inherent property of conducting materials-the limit of current density they can withstand before failure. This property, known as ampacity, is close to reaching its limits at the current scales of use, and the performances of some conductors such as gold or copper suffer severely from it. The need to find alternative conductors with higher ampacity is, therefore, an urgent need, but at the same time, one which requires simultaneous search for decreased density if it is to succeed in an ever-growing electronical world. The uses of these carbon nanotube-based materials, from airplane lightning strike protection systems to the microchip industry, will be evaluated, failure mechanisms at maximum current densities explained, limitations and difficulties in ampacity measurements with different size ranges evaluated, and future lines of research suggested. This review will therefore provide an in-depth view of the rare properties that make carbon nanotubes and their hybrids unique.

Copper/carbon nanotube composites: research trends and outlook

We present research progress made in developing copper/carbon nanotube composites (Cu/CNT) to fulfil a growing demand for lighter copper substitutes with superior electrical, thermal and mechanical performances. Lighter alternatives to heavy copper electrical and data wiring are needed in automobiles and aircrafts to enhance fuel efficiencies. In electronics, better interconnects and thermal management components than copper with higher current- and heat-stabilities are required to enable device miniaturization with increased functionality. Our literature survey encouragingly indicates that Cu/CNT performances (electrical, thermal and mechanical) reported so far rival that of Cu, proving the material's viability as a Cu alternative. We identify two grand challenges to be solved for Cu/CNT to replace copper in real-life applications. The first grand challenge is to fabricate Cu/CNT with overall performances exceeding that of copper. To address this challenge, we propose research directions to fabricate Cu/CNT closer to ideal composites theoretically predicted to surpass Cu performances (i.e. those containing uniformly distributed Cu and individually aligned CNTs with beneficial CNT-Cu interactions). The second grand challenge is to industrialize and transfer Cu/CNT from lab bench to real-life use. Toward this, we identify and propose strategies to address market-dependent issues for niche/mainstream applications. The current best Cu/CNT performances already qualify for application in niche electronic device markets as high-end interconnects. However, mainstream Cu/CNT application as copper replacements in conventional electronics and in electrical/data wires are long-term goals, needing inexpensive mass-production by methods aligned with existing industrial practices. Mainstream electronics require cheap CNT template-making and electrodeposition procedures, while data/electrical cables require manufacture protocols based on co-electrodeposition or melt-processing. We note (with examples) that initiatives devoted to Cu/CNT manufacturing for both types of mainstream applications are underway. With sustained research on Cu/CNT and accelerating its real-life application, we expect the successful evolution of highly functional, efficient, and sustainable next-generation electrical and electronics systems.

Ni Nanobuffer Layer Provides Light-Weight CNT/Cu Fibers with Superior Robustness, Conductivity, and Ampacity

Carbon nanotube (CNT) fiber has not shown its advantage as next-generation light-weight conductor due to the large contact resistance between CNTs, as reflected by its low conductivity and ampacity. Coating CNT fiber with a metal layer like Cu has become an effective solution to this problem. However, the weak CNT-Cu interfacial bonding significantly limits the mechanical and electrical performances. Here, we report that a strong CNT-Cu interface can be formed by introducing a Ni nanobuffer layer before depositing the Cu layer. The Ni nanobuffer layer remarkably promotes the load and heat transfer efficiencies between the CNT fiber and Cu layer and improves the quality of the deposited Cu layer. As a result, the new composite fiber with a 2 μm thick Cu layer can exhibit a superhigh effective strength >800 MPa, electrical conductivity >2 × 10⁷ S/m, and ampacity >1 × 10⁵ A/cm². The composite fiber can also sustain 10 000 times of bending and continuously work for 100 h at 90% ampacity.

Chromium carbide/Carbon Nanotube Hybrid Structure Assisted Copper Composites with Low Temperature Coefficient of Resistance

In order to explore the possibility of using carbon nanotube (CNT) to introduce and control the temperature coefficient of resistance (TCR) of metal matrix composite, relatively thick and short multi-walled CNTs (MWCNTs) were introduced in the metal matrix with in-situ formation of chromium carbide (Cr₇C₃) at the CNT/copper (Cu) interface. We demonstrate that incompatible properties such as electrical conductivity and TCR can be achieved simultaneously by introducing MWCNTs in the Cu matrix, with control of the interfacial resistivity using the MWCNT/Cr₇C₃–Cu system. High electrical conductivity of 94.66 IACS and low TCR of 1,451 10^–6 °C⁻¹ are achieved in the 5 vol.% MWCNT–CuCr composite. In-situ formation of Cr₇C₃ nanostructures at the MWCNT/Cu interface by reaction of diffused Cr atoms and amorphous carbon of MWCNTs would assist in improving the electrical properties of the MWCNT–CuCr composites.

Wrinkle-stabilized metal-graphene hybrid fibers with zero temperature coefficient of resistance

The interfacial adhesion between graphene and metals is poor, as metals tend to generate superlubricity on smooth graphene surface. This problem renders the free assembly of graphene and metals to be a big challenge, and therefore, some desired conducting properties (e.g., stable metal-like conductivities in air, lightweight yet flexible conductors, and ultralow temperature coefficient of resistance, TCR) likely being realized by integrating the merits of graphene and metals remains at a theoretical level. This work proposes a wrinkle-stabilized approach to address the poor adhesion between graphene surface and metals. Cyclic voltammetry (CV) tests and theoretical analysis by Scharifker-Hills models demonstrate that multiscale wrinkles effectively induce nucleation of metal particles, locking in metal nuclei and guiding the continuous growth of metal islands in an instantaneous model on rough graphene surface. The universality and practicability of the wrinkle-stabilized approach is verified by our investigation through the electrodeposition of nine kinds of metals on graphene fibers (GF). The strong interface bonding permits metal-graphene hybrid fibers to show metal-level conductivities (up to 2.2 × 10⁷ S m^-1, a record high value for GF in air), reliable weatherability and favorable flexibility. Due to the negative TCR of graphene and positive TCR of metals, the TCR of Cu- and Au-coated GFs reaches zero at a wide temperature range (15 K-300 K). For this layered model, the quantitative analysis by classical theories demonstrates the suitable thickness ratio of graphene layer and metal layer to achieve zero TCR to be 0.2, agreeing well with our experimental results. This wrinkle-stabilized approach and our theoretical analysis of zero-TCR behavior of the graphene-metal system are conducive to the design of high-performance conducting materials based on graphene and metals.

Electrical performance of lightweight CNT-Cu composite wires impacted by surface and internal Cu spatial distribution

We report ultralong conducting lightweight multiwall carbon nanotube (MWCNT)-Cu composite wires with MWCNTs uniformly distributed in a continuous Cu matrix throughout. With a high MWCNT vol% (40-45%), the MWCNT-Cu wire density was 2/3rd that of Cu. Our composite wires show manufacturing potential because we used industrially compatible Cu electrodeposition protocols on commercial CNT wires. Further, we systematically varied Cu spatial distribution on the composite wire surface and bulk and measured the associated electrical performance, including resistivity (ρ), temperature dependence of resistance, and stability to current (measured as current carrying capacity, CCC in vacuum). We find that a continuous Cu matrix with homogeneous MWCNT distribution, i.e., maximum internal Cu filling within MWCNT wires, is critical to high overall electrical performances. Wires with maximum internal Cu filling exhibit (i) low room temperature ρ, 1/100th of the starting MWCNT wires, (ii) suppressed resistance-rise with temperature-increase and temperature coefficient of resistance (TCR) ½ that of Cu, and (iii) vacuum-CCC 28% higher than Cu. Further, the wires showed real-world applicability and were easily soldered into practical circuits. Hence, our MWCNT-Cu wires are promising lightweight alternatives to Cu wiring for weight-reducing applications. The low TCR is specifically advantageous for stable high-temperature operation, e.g., in motor windings.

Understanding the Effect of Functional Groups on the Seeded Growth of Copper on Carbon Nanotubes for Optimizing Electrical Transmission

We present a study of the seeded growth of copper on the surface of two classes of single-walled carbon nanotubes (SWNTs) in order to compare the effects of surface functional groups. Pyridine-functionalized HiPco SWNTs and ultrashort SWNTs (US-SWNTs) were synthesized (py-SWNTs and py-US-SWNTs, respectively), and the functionality was used as seed sites for copper, via an aqueous electroless deposition reaction, as a comparison to the carboxylic acid functionality present on piranha-etched SWNTs and the native US-SWNTs. UV-vis spectroscopy demonstrated the take-up of Cu(II) ions by the functionalized SWNTs. TEM showed that the SWNTs with pyridine functionality more rapidly produced a more even distribution of copper seeds with a narrower size distribution (3-12 nm for py-US-SWNTs) than those SWNTs with oxygen functional groups (ca. 30 nm), showing the adventitious role of the pyridine functional group in the seeding process. Seed composition was confirmed as Cu(0) by XPS and SAED. Copper growth rate and morphology were shown to be affected by degree of pyridine functionality, the length of the SWNT, and the electroless reaction solvent used.

Carbon-Nanotube Fibers for Wearable Devices and Smart Textiles

Carbon-nanotube (CNT) fibers integrate such properties as high mechanical strength, extraordinary structural flexibility, high thermal and electrical conductivities, novel corrosion and oxidation resistivities, and high surface area, which makes them a very promising candidate for next-generation smart textiles and wearable devices. A brief review of the preparation of CNT fibers and recently developed CNT-fiber-based flexible and functional devices, which include artificial muscles, electrochemical double-layer capacitors, lithium-ion batteries, solar cells, and memristors, is presented.

Post-Treatments for Multifunctional Property Enhancement of Carbon Nanotube Fibers from the Floating Catalyst Method

We investigated the effects of the synthesis conditions and condensation processes on the chemical compositions and multifunctional performance of the directly spun carbon nanotube (CNT) fibers. On the basis of the optimized synthesis conditions, a two-step post-treatment technique which involved acidification and epoxy infiltration was also developed to further enhance their mechanical and electrical properties. As a result, their tensile strength and Young's modulus increased remarkably by 177% and 325%, respectively, while their electrical conductivity also reached 8235 S/cm. This work may provide a general strategy for the postprocessing optimization of the directly spun CNT fibers. The treated CNT fibers with superior properties are promising for a wide range of applications, such as structural reinforcements and lightweight electric cables.

Electro-induced mechanical and thermal responses of carbon nanotube fibers

The electromechanical and electrothermal responses of carbon nanotube fibers provide new ways to use energy conversion, including the modulation of assembly structures by alternative densification and relaxation. The most efficient way to strengthen the tensile strength up to 2.32-2.50 GPa is shown as well as a microscale, nanotube-based Chinese calligraphy brush.

One hundred fold increase in current carrying capacity in a carbon nanotube-copper composite

Increased portability, versatility and ubiquity of electronics devices are a result of their progressive miniaturization, requiring current flow through narrow channels. Present-day devices operate close to the maximum current-carrying-capacity (that is, ampacity) of conductors (such as copper and gold), leading to decreased lifetime and performance, creating demand for new conductors with higher ampacity. Ampacity represents the maximum current-carrying capacity of the object that depends both on the structure and material. Here we report a carbon nanotube–copper composite exhibiting similar conductivity (2.3–4.7 × 10⁵ S cm⁻¹) as copper (5.8 × 10⁵ S cm⁻¹), but with a 100-times higher ampacity (6 × 10⁸ A cm⁻²). Vacuum experiments demonstrate that carbon nanotubes suppress the primary failure pathways in copper as observed by the increased copper diffusion activation energy (∼2.0 eV) in carbon nanotube–copper composite, explaining its higher ampacity. This is the only material with both high conductivity and high ampacity, making it uniquely suited for applications in microscale electronics and inverters.

High electrical conductivity and ampacity are usually mutually exclusive properties. Here, in a carbon nanotube–copper composite, Subramaniam et al. achieve a similar conductivity to copper, but with a hundred fold increase in current carrying capacity.

Carbon nanotube fibers for electrochemical applications: effect of enhanced interfaces by an acid treatment

Chemical treatment using concentrated nitric acid (16 M) not only induced significant improvement of mechanical and electrical properties of carbon nanotube fibers due to the enhanced interfacial interaction but also allowed much more efficient deposition of polyaniline for developing fiber-shaped supercapacitors. After the 2 h treatment, the acidized fiber had a tensile strength of 1.52 GPa and an electrical conductivity of 1050 S cm(-1), increased by 52% and 128%, respectively, compared with the untreated one. By depositing polyaniline for 10 min around the fiber, the composite fiber had a volumetric capacitance of 239 F cm(-3), 17% higher than that without the acid treatment. For a long time treatment up to 6 h, although the strength and conductivity decreased slightly, the composite fiber had a super high volumetric capacitance up to 299 F cm(-3). The improvement of electrochemical performance is attributed to the increased deposition rate and structural change of polyaniline due to the existence of functional groups on the fiber surface.

High-performance, lightweight coaxial cable from carbon nanotube conductors

Coaxial cables have been constructed with carbon nanotube (CNT) materials serving as both the inner and outer conductors. Treatment of the CNT outer and inner conductors with KAuBr(4) was found to significantly reduce the attenuation of these cables, which demonstrates that chemical agents can be used to improve power transmission through CNT networks at high frequencies (150 kHz-3 GHz). For cables constructed with a KAuBr(4)-treated CNT outer conductor, power attenuation per length approaches parity with cables constructed from metallic conductors at significantly lower weight per length (i.e., 7.1 g/m for CNT designs compared to 38.8 g/m for an RG-58 design). A relationship between the thickness of the CNT outer conductor and the cable attenuation was observed and used to estimate the effective skin depth at high frequency. These results establish reliable, reproducible methods for the construction of coaxial cables from CNT materials that can facilitate further investigation of their performance in high-frequency transmission structures, and highlight a specific opportunity for significant reduction in coaxial cable mass.