In situ measurements and modeling of carbon nanotube array growth kinetics during chemical vapor deposition

Direct measurements of carbon nanotube growth kinetics are described based upon time-resolved reflectivity (TRR) of a HeNe laser beam from vertically aligned nanotube arrays (VANTAs) as they grow during chemical vapor deposition (CVD). Growth rates and terminal lengths were measured in situ for VANTAs growing during CVD between 535 °C and 900 °C on Si substrates with evaporated Al/Fe/Mo multi-layered catalysts and acetylene feedstock at different feedstock partial pressures. Methods of analysis of the TRR signals are presented to interpret catalyst particle formation and oxidation, as well as the porosity of the VANTAs. A rate-equation model is developed to describe the measured kinetics in terms of activation energies and rate constants for surface carbon formation and diffusion on the catalyst nanoparticle, nanotube growth, and catalyst over-coating. Taken together with the TRR data, this model enables basic understanding and optimization of growth conditions for any catalyst/feedstock combination. The model lends insight into the main processes responsible for the growth of VANTAs, the measured number of walls in the nanotubes at different temperatures, conditions for growth of single-wall carbon nanotube arrays, and likely catalyst poisoning mechanisms responsible for the sharp decline in growth rates observed at high temperatures. PACS  61.46.+w; 81.07.De; 81.16.Hc     

Synthesis of carbon nanotubes by ECR plasma-assisted chemical vapor deposition

Carbon nanotubes have been grown using an electron cyclotron resonance (ECR) plasma source at a substrate temperature of 500 °C. Methane has been used as the source gas. A network of carbon nanotubes has been observed in scanning electron microscopy. Transmission electron microscopy revealed that the structure consists of straight, Y-junction and ring-like nanotubes. Further, electron diffraction of the nanotubes confirms a graphite crystal structure. PACS 81.16.He; 68.37.Lp; 68.37.Hk; 85.35.Kt; 75.75.+a     

Growth of Y-junction bamboo-shaped CNx nanotubes on GaAs substrate using single feedstock

Nitrogen-doped Y-junction bamboo-shaped carbon nanotubes were synthesized by chemical vapor deposition of monoethanolamine/ferrocene mixture on GaAs substrate at 950 °C. The use of monoethanolamine as the C/N feedstock simplifies the experimental arrangement by producing ammonia during the growth process. The structure, morphology and graphitization of as-grown nitrogen-doped carbon nanotubes (CN_x) were examined by scanning electron microscopy (SEM), transmission electron microscopy (TEM) and Raman spectroscopy analysis. TEM analysis indicates that nanotubes have a bamboo-like structure. The nitrogen concentration on as-grown CN_x nanotube was found to be 7.8 at.% by X-ray photoelectron spectroscopy (XPS) analysis. XPS analysis also indicated that there are two different types of nitrogen atoms (pyridinic and graphitic) in these materials. The possible growth mechanism of formation of Y-junction CN_x nanotubes was briefly discussed. Field emission measurement suggested that as-grown CN_x nanotubes are excellent emitters with turn-on and threshold fields of 1.6 and 2.63 V/μm, respectively. The result indicated that monoethanolamine proves to be an advantageous precursor to synthesize Y-junction nitrogen-doped carbon nanotubes and such nanotubes might be an effective material to fabricate various field emission devices.     

Scanning the laser beam for ultrafast pulse laser cleaning of paint

Aligned arrays of N₂-encapsulated multilevel branched carbon nanotubes were synthesized using a simple one step CVD method by pyrolysis of ferrocene and acetonitrile. Electron energy loss spectroscopy (EELS) and elemental mapping studies reveal that gaseous nitrogen was encapsulated in the carbon nanotubes. Batch-type pyrolysis of catalysts induced flow fluctuation of the reaction gases, resulting in the growth of branched junctions. Molecular nitrogen extruded rapidly along conical catalyst particles inducing N₂ encapsulation inside the branched nanotubes. PACS 07.78.+s; 61.46.+w; 81.07.De; 81.15.Gh     

Hydrogen-free spray pyrolysis chemical vapor deposition method for the carbon nanotube growth: Parametric studies

Spray pyrolysis chemical vapor deposition (CVD) in the absence of hydrogen at low carrier gas flow rates has been used for the growth of carbon nanotubes (CNTs). A parametric study of the carbon nanotube growth has been conducted by optimizing various parameters such as temperature, injection speed, precursor volume, and catalyst concentration. Experimental observations and characterizations reveal that the growth rate, size and quality of the carbon nanotubes are significantly dependent on the reaction parameters. Scanning electron microscopy, transmission electron microscopy, and Raman spectroscopy techniques were employed to characterize the morphology, structure and crystallinity of the carbon nanotubes. The synthesis process can be applied to both semiconducting silicon wafer and conducting substrates such as carbon microfibers and stainless steel plates. This approach promises great potential in building various nanodevices with different electron conducting requirements. In addition, the absence of hydrogen as a carrier gas and the relatively low synthesis temperature (typically 750 °C) qualify the spray pyrolysis CVD method as a safe and easy way to scale up the CNT growth, which is applicable in industrial production.     

Formation of Y-junction carbon nanotubes by catalytic CVD of methane

Y-junction carbon nanotubes were grown by catalytic CVD of methane at 700 ^°C on NiO-CuO-MoO(7:2:1) (w/w/w)/SiO₂ catalyst. For comparison, NiO-CuO(8:2) (w/w)/SiO₂ and NiO-MoO(8:2) (w/w)/SiO₂ catalysts were tested for carbon nanotube formation. TEM analysis indicates that no Y-junction structures were formed with the latter two catalysts. This finding elucidates why the addition of a small amount of MoO to NiO-CuO/SiO₂ catalyst is crucial for enhancing the formation of Y-junction carbon nanotubes.     

Novel room temperature ionic liquids of hexaalkyl substituted guanidinium salts for dye-sensitized solar cells

Nanoparticles are attracting increasing interest because of their high potential for a great number of practical applications, such as optical and electronic devices, nanoscale storage, and delivery systems. Using Cu-phthalocyanine as precursor material, we have synthesized multi-shell graphitic carbon nanospheres without and with metal encapsulation, depending on the pyrolysis conditions. The encapsulated elemental copper nanocrystals achieved using that route were of the order of 50 nm in size. The particles were characterized in detail by high-resolution transmission electron microscopy (HRTEM) and by energy filtering microscopy (EFTEM). The concentric graphitic carbon shells of the as-grown particles were clearly discernable. After in situ high-temperature annealing, an increase in the degree of order was observed. Under high-voltage electron irradiation and heating, a melting point reduction of the enclosed nanosized copper of more than 200 K could be detected, as compared to the melting point 1083 °C of bulk copper. Time-resolved imaging revealed the displacement of the melting copper by migration through the carbon shells, leaving intact carbon cages with a central hole. At intermediate stages of this process the transformation into a hexagonal morphology of the copper nanocrystals was observed. PACS 61.46.+w; 61.48.+c; 68.37.Lp     

New aspects on pulsed laser deposition of aligned carbon nanotubes

We have grown carbon nanotubes (CNT) by pulsed laser deposition (PLD) at 1000 °C in Ar atmosphere. A Nd/YAG laser was used for irradiation of a graphite target containing Ni and Co rods. High-resolution scanning electron microscopy (HRSEM) and transmission electron microscopy (TEM) images showed that “closed” carbon nanotubes were grown between clusters of metallic particles, so that the individual nanotubes were arranged in parallel to each other forming a shape of “Rope-Bridge”. The nanotubes structure was analyzed by high-resolution transmission electron microscopy (HRTEM) and their type was found to be of MWNT, containing about five SWNT. Total diameter was 5-20 nm and their length was about 1 μm. High homogeneous distribution carbon nanotubes were grown and different structures were observed such as well-aligned carbon nanotubes, bamboo-like and Y-junction carbon nanotubes.     

Temperature and substrate dependence of structure and growth mechanism of carbon nanofiber

The carbon nanofibers were grown on Ni/Si and Ni/Ti/Si substrates in 1 atm CH₄ atmosphere at 640 °C and 700 °C by thermal chemical vapor deposition method. The carbon nanofibers were characterized by field emission scanning electron microscopy, transmission electron microscopy, and Raman spectrometry for morphology, microstructure, and crystallinity. The electron emission property of carbon nanofibers was also investigated by current-voltage (I-V) measurement. The results showed that the solid amorphous carbon nanofibers could be grown on Ni/Si substrate at 640 °C through tip growth mechanism, the carbon nanotubes could be grown on Ni/Si substrate at 700 °C through tip growth mechanism, and the carbon nanotubes could be grown on Ni/Ti/Si substrate at 700 °C through root growth mechanism.     

Temperature-controlled catalytic growth of one-dimensional gallium nitride nanostructures using a gallium organometallic precursor

Catalytic growth of 1-D GaN nanostructures is achieved at temperatures from 550 to 850 °C using NH₃ and gallium acetylacetonate. Structural characterization of the 1-D GaN nanostructures by HRTEM shows that straight GaN nanowires, needle-like nanowires (nanoneedles), and bamboo-shoot-like nanoneedles are synthesized at 750, 650, and 550 °C, respectively. In addition to selecting a proper catalyst, providing sufficient precursors has been demonstrated to be a crucial factor for the low-temperature growth of 1-D GaN nanostructures via the VLS mechanism. Possible mechanisms for forming nanoneedles at low temperatures are proposed. PACS 61.46.+w; 68.65.–k; 81.07.–b     

The synthesis of multi-walled carbon nanotubes (MWNTs) by catalytic pyrolysis of the phenol-formaldehyde resins

A series of carbon nanomaterials, particularly multi-walled carbon nanotubes (MWNT), are obtained as products from catalytic pyrolysis of the cross-linked phenol-formaldehyde resins with different ferrocene under inert atmosphere. The morphology and structure of the samples were evaluated by TEM and XRD techniques. CNTs morphology is dependent on the iron nanoparticles and their forms (Fe, Fe₃C) resulted from ferrocene decomposition. The amount of nanotubes increases with iron content released from ferrocene catalyst during the pyrolysis process. Fe₃C nanoparticles drive the nucleation and the growth of carbon nanotubes during the pyrolysis process. Long (up to microns) well-defined MWNTs with small defects, ropes and disordered carbon are representatives in the pyrolyzed resins composition.     

Selective growth, characterization, and field emission performance of single-walled and few-walled carbon nanotubes by plasma enhanced chemical vapor deposition

Single-walled carbon nanotubes (SWCNTs) and few-walled carbon nanotubes (FWCNTs) have been selectively synthesized by plasma enhanced chemical vapor deposition at a relative low temperature (550 °C) by tuning the thickness of iron catalyst. The parametric study and the optimization of the nanotube growth were undertaken by varying inductive power, temperature, catalyst thickness, and plasma to substrate distance. When an iron film of 3-5 nm represented the catalyst thickness for growing FWCNT arrays, SWCNTs were synthesized by decreasing the catalyst thickness to 1 nm. The nanotubes were characterized by field emission scanning electron microscopy, transmission electron microscopy, and Raman spectroscopy. Electron field emission properties of the nanotubes indicate that the SWCNTs exhibit lower turn-on field compared to the FWCNTs, implying better field emission performance.     

Synthesis and crystallinity of carbon nanotubes produced by a vapor-phase growth method

We have studied the effect of temperature on the growth and crystallinity of carbon nanotubes (CNTs), synthesized by a vapor-phase growth method using a catalytic reaction of iron pentacarbonyl (Fe(CO)₅) and acetylene (C₂H₂) gas. By increasing the growth temperature from 750 °C to 950 °C, both the growth rate and the diameter of the CNTs increase. Moreover, the crystallinity of the graphite sheets improves progressively with increasing growth temperature. Adjustment of the growth temperature gives potential for controlled growth of CNTs in a large-scale synthesis of CNTs. PACS 61.46.+w; 68.37.-d; 81.07.De     

Experimental study of the influence of hydrogenation on synthesis of carbon nanostructures in a reactor with activated hydrogen

The role of backward pyrolysis of carbon during hydrogenation of unstructured carbon black and nanotube growth in a reactor with hydrogen activated by diffusion through a heated metallic wall is studied. If the wall is heated nonuniformly, the amorphous unstructured carbon deposit “climbs” in the course of hydrogenation by active hydrogen and deposits again when falling on the heated metal surface, self-organizing into more ordered nanofibers and nanotubes as a result of forward pyrolysis. It is shown that this effect can be used for raising the concentration of carbon nanotubes growing on catalyst particles in the deposited layer.     

Influence of heat treatment on tribological properties of electroless Ni-P and Ni-P-Al2O3 coatings on Al-Si casting alloy

Evolution of tribological properties of electroless Ni-P and Ni-P-Al₂O₃ coating on an Al-10Si-0.3Mg casting alloy during heat treatment is investigated in this work. The pre-treated substrate was plated using a bath containing nickel hypophosphite, nickel lactate and lactic acid. For preparation of fiber-reinforced coating Al₂O₃ Saffil fibers pre-treated in demineralised water were used. The coated samples were heat treated at 400-550 °C/1-8 h. Tribological properties were studied using the pin-on-disc method. It is found that the best coating performance is obtained using optimal heat treatment regime (400 °C/1 h). Annealing at higher temperatures (450 °C and above) leads to the formation of intermetallic compounds that reduce the coating wear resistance. The reason is that the intermetallic phases adversely affect the coating adherence to the substrate. The analysis of wear tracks proves that abrasion is major wear mechanism, however due to the formed intermetallic sub-layers, partial coating delamination may occur during the pin-on-disc test on the samples annealed at 450 °C and above. It was found that fiber reinforcement reduces this scaling and increases wear resistance of coatings as compared to the non-reinforced Ni-P coatings.     

Formation of bamboo-shaped carbon nanotubes on carbon black in a fluidized bed

For the first time, bamboo-shaped multiwalled carbon nanotubes, having diameter of the order of 50 nm, have been grown on carbon black in a fluidized bed in bulk amount. The activation energy for the synthesis of the product was found out to be around 33 kJ/mol in the temperature range of 700−900 °C. The carbon nanotubes were separated from the carbon black by preferential oxidation of the later, the temperature of which was determined by thermogravimetry. The transmission electron microscopy revealed different features of the nanotubes such as “Y” junction, bend, and catalyst filling inside the nanotubes. Small angle neutron scattering was performed on the nanotubes synthesized at different temperatures. The data were fitted into a suitable model in order to find out the average diameter, which decreases with increase in synthesis temperature. The Monte Carlo simulation predicts the same behavior. Based on the above observations, a possible growth mechanism has been predicted. The oscillation in carbon saturation value inside the catalyst in the fluidized bed has been indicated as the responsible factor for the bamboo-shaped structure.     

Growth of single-walled carbon nanotubes from size-selected catalytic metal particles

Single-walled carbon nanotubes (SWNTs) were synthesized using size-controlled catalyst nanoparticles created by the pulsed laser ablation method. Specifically, the alloy particles (Co/Mo or Co/Pt) were prepared by ablation of the target alloy materials in an inert gas atmosphere. Size selection was performed using a differential mobility analyzer (DMA). The obtained nanoparticles were deposited on a quartz substrate from which SWNTs were grown by the alcohol catalytic CVD (ACCVD) technique that was developed by the authors group. AFM and Raman scattering analysis revealed that SWNTs were successfully synthesized. It seems the Co/Mo alloy catalyst was more effective for the synthesis of SWNTs than the Co/Pt catalyst, though this is a preliminary result to be further investigated. PACS 36.40.-c; 61.46.+w; 65.80.+n; 78.30.Na; 81.07.de     

Effect of catalyst preparation on the yield of carbon nanotube growth

Multi-wall carbon nanotubes (MWCNTs) were synthesized by catalytic chemical vapor deposition (CVD) on catalytic iron nanoparticles dispersed in a silica matrix, prepared by sol gel method. In this contribution, variation of gelation condition on catalyst structure and its influence on the yield of carbon nanotubes growth was studied. The precursor utilized were tetraethyl-orthosilicate and iron nitrate. The sols were dried at two different temperatures in air (25 or 80 °C) and then treated at 450 °C for 10 h. The xerogels were introduced into the chamber and reduced in a hydrogen/nitrogen (10%v/v) atmosphere at 600 °C. MWCNTs were formed by deposition of carbon atoms from decomposition of acetylene at 700 °C. The system gelled at RT shows a yield of 100% respect to initial catalyst mass whereas the yield of that gelled at 80 °C was lower than 10%. Different crystalline phases are observed for both catalysts in each step of the process. Moreover, TPR analysis shows that iron oxide can be efficiently reduced to metallic iron only in the system gelled at room temperature. Carbon nanotubes display a diameter of about 25–40 nm and several micron lengths. The growth mechanism of MWCNTs is base growth mode for both catalysts.     

Distinguishing the impact of temperature on iron catalyst during the catalytic-pyrolysis of waste polypropylene

The catalytic pyrolysis of waste plastics with iron-based catalyst can produce H₂ rich gas, liquid oil and carbon nanotube (CNTs) together. While the catalytic pyrolysis mechanism is still unclear, in this study, the catalytic pyrolysis of polypropylene (PP) was explored in depth, and the influence of catalyst and temperature was distinguished. The results indicated that a lower temperature led to the generation of waxes, while a higher temperature promoted the formation of aromatic hydrocarbons when plastic pyrolysis was performed without a catalyst. In addition, a large number of carbon deposits, mainly in the form of spheres, were collected when the temperature was over 800 ℃. These carbon spheres originated from the agglomeration of aromatic hydrocarbons. Once catalysts were introduced, a large amount of liquid oil was transferred into carbon deposits at both lower and higher catalytic temperatures, simultaneously, leading to more light gases releasing, like hydrogen. At a lower temperature (≤ 800 ℃), it was mainly CNTs while carbon spheres are the main solid product at higher temperatures (> 800 ℃). In addition, two different mechanisms of CNTs formation were also concluded that the base-growth model dominated the of generation CNTs at 600 °C whereas the CNTs followed the tip-growth model at 800 ℃. The results show that the optimized temperature for the catalytic process should be around 800 ^o℃ where approximately 35 mmol/g_plastic hydrogen, 50% hydrogen efficiency and over 320 mg/g_plastic carbon nanotubes (CNTs) were obtained.     

Synthesis of carbon nanotubes by CVD: Effect of acetylene pressure on nanotubes characteristics

The effect of acetylene partial pressure on the structural and morphological properties of multi-walled carbon nanotubes (MWCNTs) synthesized by CVD on iron nanoparticles dispersed in a SiO₂ matrix as catalyst was investigated. The general growing conditions were: 110 cm³/min flow rate, 690 °C synthesis temperature, 180 Torr over pressure and two gas compositions: 2.5% and 10% C₂H₂/N₂. The catalyst and nanotubes were characterized by HR-TEM, SEM and DRX. TGA and DTA were also carried out to study degradation stages of synthesized CNTs. MWCNTs synthesized with low acetylene concentration are more regular and with a lower amount of amorphous carbon than those synthesized with a high concentration. During the synthesis of CNTs, amorphous carbon nanoparticles nucleate on the external wall of the nanotubes. At high acetylene concentration carbon nanoparticles grow, covering all CNTs’ surface, forming a compact coating. The combination of CNTs with this coating of amorphous carbon nanoparticles lead to a material with high decomposition temperature.