The role of sulphur in the synthesis of carbon nanotubes by chemical vapour deposition at high temperatures

Molecular dynamics simulation of carbon nanotube growth under a tensile strain

We performed molecular dynamics simulations of carbon nanotube (CNT) to elucidate the growth process in the floating catalyst chemical vapor deposition method (FCCVD). FCCVD has two features: a nanometer-sized cementite (Fe3 C) particle whose melting point is depressed because of the larger surface-to-volume ratio and tensile strain between the growing CNT and the catalyst. The simulations, including these effects, demonstrated that the number of 6-membered rings of the (6,4) chiral CNT constantly increased at a speed of 1 mm / s at 1273 K , whereas those of the armchair and zigzag CNTs were stopped in the simulations and only reached half of the numbers for chiral CNT. Both the temperature and CNT chirality significantly affected CNT growth under tensile strain.

Gas-to-nanotextile: high-performance materials from floating 1D nanoparticles

Suspended in the gas phase, 1D inorganic nanoparticles (nanotubes and nanowires) grow to hundreds of microns in a second and can be thus directly assembled into freestanding network materials. The corresponding process continuously transforms gas precursors into aerosols into aerogels into macroscopic nanotextiles. By enabling the assembly of very high aspect ratio nanoparticles, this processing route has translated into high-performance structural materials, transparent conductors and battery anodes, amongst other embodiments. This paper reviews progress in the application of such manufacturing process to nanotubes and nanowires. It analyses 1D nanoparticle growth through floating catalyst chemical vapour deposition (FCCVD), in terms of reaction selectivity, scalability and its inherently ultra-fast growth rates (10⁷-10⁸ atoms per second) up to 1000 times faster than for substrate CVD. We summarise emerging descriptions of the formation of aerogels through percolation theory and multi-scale models for the collision and aggregation of 1D nanoparticles. The paper shows that macroscopic ensembles of 1D nanoparticles resemble textiles in their porous network structure, high flexibility and damage-tolerance. Their bulk properties depend strongly on inter-particle properties and are dominated by alignment and volume fraction. Selected examples of nanotextiles that surpass granular and monolithic materials include structural fibres with polymer-like toughness, transparent conductors, and slurry-free composite electrodes for energy storage.

Synthesis of Ultralong Carbon Nanotubes with Ultrahigh Yields

Ultralong carbon nanotubes (CNTs) are in huge demand in many cutting-edge fields due to their macroscale lengths, perfect structures, and extraordinary properties, while their practical application is limited by the difficulties in their mass production. Herein, we report the synthesis of ultralong CNTs with a dramatically increased yield by a simple but efficient substrate interception and direction strategy (SIDS), which couples the advantages of floating-catalyst chemical vapor deposition with the flying-kite-like growth mechanism of ultralong CNTs. The SIDS-assisted approach prominently improves the catalyst utilization and significantly increases the yield. The areal density of the ultralong CNT arrays with length of over 1 cm reached a record-breaking value of ∼6700 CNTs mm^-1, which is 2-3 orders of magnitude higher than the previously reported values obtained by traditional methods. The SIDS provides a solution for synthesizing high-quality ultralong CNTs with high yields, laying the foundation for their mass production.

Superstrong Carbon Nanotube Yarns by Developing Multiscale Bundle Structures on the Direct Spin-Line without Post-Treatment

Super strong fibers, such as carbon or aramid fibers, have long been used as effective fillers for advanced composites. In this study, the highest tensile strength of 5.5 N tex^-1 for carbon nanotube yarns (CNTYs) is achieved by controlling the micro-textural structure through a facile and eco-friendly bundle engineering process in direct spinning without any post-treatment. Inspired by the strengthening mechanism of the hierarchical fibrillary structure of natural cellulose fiber, this study develops multiscale bundle structures in CNTYs whereby secondary bundles, ≈200 nm in thickness, evolve from the assembly of elementary bundles, 30 nm in thickness, without any damage, which is a basic load-bearing element in CNTY. The excellent mechanical performance of these CNTYs makes them promising substitutes for the benchmark, lightweight, and super strong commercial fibers used for energy-saving structural materials. These findings address how the tensile strength of CNTY can be improved without additional post-treatment in the spinning process if the development of the aforementioned secondary bundles and the corresponding orientations are properly engineered.

Graphene/PVA buckypaper for strain sensing application

Strain sensors in the form of buckypaper (BP) infiltrated with various polymers are considered a viable option for strain sensor applications such as structural health monitoring and human motion detection. Graphene has outstanding properties in terms of strength, heat and current conduction, optics, and many more. However, graphene in the form of BP has not been considered earlier for strain sensing applications. In this work, graphene-based BP infiltrated with polyvinyl alcohol (PVA) was synthesized by vacuum filtration technique and polymer intercalation. First, Graphene oxide (GO) was prepared via treatment with sulphuric acid and nitric acid. Whereas, to obtain high-quality BP, GO was sonicated in ethanol for 20 min with sonication intensity of 60%. FTIR studies confirmed the oxygenated groups on the surface of GO while the dispersion characteristics were validated using zeta potential analysis. The nanocomposite was synthesized by varying BP and PVA concentrations. Mechanical and electrical properties were measured using a computerized tensile testing machine, two probe method, and hall effect, respectively. The electrical conducting properties of the nanocomposites decreased with increasing PVA content; likewise, electron mobility also decreased while electrical resistance increased. The optimization study reports the highest mechanical properties such as tensile strength, Young’s Modulus, and elongation at break of 200.55 MPa, 6.59 GPa, and 6.79%, respectively. Finally, electrochemical testing in a strain range of ε ~ 4% also testifies superior strain sensing properties of 60 wt% graphene BP/PVA with a demonstration of repeatability, accuracy, and preciseness for five loading and unloading cycles with a gauge factor of 1.33. Thus, results prove the usefulness of the nanocomposite for commercial and industrial applications.

High throughput production of single-wall carbon nanotube fibres independent of sulfur-source

Floating catalyst chemical vapor deposition (FC-CVD) methods offer a highly scalable strategy for single-step synthesis and assembly of carbon nanotubes (CNTs) into macroscopic textiles. However, the non-uniform axial temperature profile of a typical reactor, and differing precursor breakdown temperatures, result in a broad distribution of catalyst particle sizes. Spun CNT fibres therefore contain nanotubes with varying diameters and wall numbers. Herein, we describe a general FC-CVD approach to obtain relatively large yields of predominantly single-wall CNT fibres, irrespective of the growth promoter (usually a sulfur compound). By increasing carrier gas (hydrogen) flow rate beyond a threshold whilst maintaining a constant C : H2 mole ratio, CNTs with narrower diameters, a high degree of graphitization (G : D ratio ∼100) and a large throughput are produced, provided S : Fe ratio is sufficiently low. Analysis of the intense Raman radial breathing modes and asymmetric G bands, and a shift in the main nanotube population from thermogravimetric data, show that with increasing flow rate, the fibres are enriched with small diameter, metallic CNTs. Transmission electron microscopy corraborates our primary observation from Raman spectroscopy that with high total flow rates, the fibres produced consist of predominantly small diameter SWCNTs.

Synthesis of polyvinyl alcohol (PVA) infiltrated MWCNTs buckypaper for strain sensing application

Buckypaper (BP)/polymer composites are viewed as a viable option to improve the strain transfer across the buckypaper strain sensor by means of providing better interfacial bonding between the polymer and carbon nanotubes (CNTs). Multiwall carbon nanotubes (MWCNTs) BP/polyvinyl alcohol (PVA) composites were fabricated by a sequence of vacuum filtration and polymer intercalation technique. The optimized conditions for achieving a uniform and stable dispersion of MWCNTs were found to be using ethanol as a dispersion medium, 54 μm ultrasonic amplitude and 40 min sonication time. FTIR analysis and SEM spectra further confirmed the introduction of oxygenated groups (-COOH) on the surface of MWCNTs BP and the complete infiltration of PVA into the porous MWCNTs network. At MWCNTs content of 65 wt. %, the tensile strength, Young's modulus and elongation-at-break of PVA-infiltrated MWCNTs BP achieved a maximum value of 156.28 MPa, 4.02 GPa and 5.85%, improved by 189%, 443% and 166% respectively, as compared to the MWCNTs BP. Electrical characterization performed using both two-point probe method and Hall effect measurement showed that BP/PVA composites exhibited reduced electrical conductivity. From the electromechanical characterization, the BP/PVA composites showed improved sensitivity with a gauge factor of about 1.89-2.92. The cyclic uniaxial tensile test validated the high reproducibility and hysteresis-free operation of 65-BP/PVA composite under 3 loading-unloading cycles. Characterization results confirmed that the flexible BP/PVA composite (65 wt. %) with improved mechanical and electromechanical properties is suitable for strain sensing applications in structural health monitoring and wearable technology, as an alternative choice to the fragile nature of conventional metallic strain sensors.

The Dependence of CNT Aerogel Synthesis on Sulfur-driven Catalyst Nucleation Processes and a Critical Catalyst Particle Mass Concentration

The floating catalyst chemical vapor deposition (FC-CVD) process permits macro-scale assembly of nanoscale materials, enabling continuous production of carbon nanotube (CNT) aerogels. Despite the intensive research in the field, fundamental uncertainties remain regarding how catalyst particle dynamics within the system influence the CNT aerogel formation, thus limiting effective scale-up. While aerogel formation in FC-CVD reactors requires a catalyst (typically iron, Fe) and a promotor (typically sulfur, S), their synergistic roles are not fully understood. This paper presents a paradigm shift in the understanding of the role of S in the process with new experimental studies identifying that S lowers the nucleation barrier of the catalyst nanoparticles. Furthermore, CNT aerogel formation requires a critical threshold of Fe_xC_y > 160 mg/m³, but is surprisingly independent of the initial catalyst diameter or number concentration. The robustness of the critical catalyst mass concentration principle is proved further by producing CNTs using alternative catalyst systems; Fe nanoparticles from a plasma spark generator and cobaltocene and nickelocene precursors. This finding provides evidence that low-cost and high throughput CNT aerogel routes may be achieved by decoupled and enhanced catalyst production and control, opening up new possibilities for large-scale CNT synthesis.

Purification and Dissolution of Carbon Nanotube Fibers Spun from the Floating Catalyst Method

In this study, we apply a simple but effective oxidative purification method to purify carbon nanotube (CNT) fibers synthesized via a floating catalyst technique. After the purification treatment, the resulting CNT fibers exhibited significant improvements in mechanical and electrical properties with an increase in strength, Young's modulus, and electrical conductivity by approximately 81, 230, and 100%, respectively. With the successful dissolution of the CNT fibers in superacid, an extensional viscosity method could be applied to measure the aspect ratio of the CNTs constituting the fibers, whereas high-purity CNT thin films could be produced with a low resistance of 720 Ω/sq at a transmittance of 85%. This work suggests that the oxidative purification approach and dissolution process are promising methods to improve the purity and performance of CNT macroscopic structures.

Carbon nanotube fibers and films: synthesis, applications and perspectives of the direct-spinning method

The direct-spinning method of creation of CNT macroassemblies has received a lot of attention because of its simplicity to produce high-performance material without apparent limits to its size. CNT fibers or films have shown unparalleled properties and opened new areas of research and commercial development. The process designed more than a decade ago has already given interesting information about the basic science of nanomaterials, which in parallel led to the creation of the first prototypes with high potential of implementation in everyday life. Because of this, there has been growing interest in this technique with research articles coming into view from all around the world on a frequent basis. This review aims to summarize all the progress made in the direct-spinning process on a spectrum of fronts ranging from the study of complex synthesis parameters, material properties to its viable applications. The strong and weak points of the "Cambridge process" are carefully evaluated to put forward what challenges are most pressing. The future overlook puts the state of the art into perspective and suggests the prospective research directions.

Inherent predominance of high chiral angle metallic carbon nanotubes in continuous fibers grown from a molten catalyst

We present evidence that high temperature CVD growth of SWNTs under conditions of continuous spinning of macroscopic fibers leads to an inherent predominance of high chiral angle CNTs, peaking at the armchair end. Raman, UV-vis-NIR absorption, and photoluminescence spectroscopy measurements show the prevalence of metallic SWNTs. The complete chiral angle distribution is obtained by electron diffraction of over 390 CNTs. It is biased towards high chiral angles and peaks at the armchair end (30°), in good agreement with the established atomistic models for SWNT growth from a liquid catalyst. Based on the Fe-C-S constituent binary and ternary phase diagrams, thermodynamic calculations of phase compositions from fast cooling and experimental evidence of a post-synthesis catalyst, the proposed thermodynamic path of the catalyst is to form a solid FCC Fe core and a liquid Fe-S shell. S in the outer liquid shell first stabilizes the edge of the nascent CNT, but once a graphitic wall forms it is rejected due to the high interfacial energy of the Fe-C-S alloy.

Synthesis of high-quality carbon nanotube fibers by controlling the effects of sulfur on the catalyst agglomeration during the direct spinning process

The effects of sulfur on the size of iron catalyst particles and synthesized carbon nanotubes (CNTs) were investigated during the direct spinning of CNT fibers.

In Situ TEM Observations on the Sulfur-Assisted Catalytic Growth of Single-Wall Carbon Nanotubes

The effect of sulfur on the catalytic nucleation and growth of single-wall carbon nanotubes (SWCNTs) from an iron catalyst was investigated in situ by transmission electron microscopy (TEM). The catalyst precursor of ferrocene and growth promoter of sulfur were selectively loaded inside of the hollow core of multiwall CNTs with open ends, which served as a nanoreactor powered by applying a voltage inside of the chamber of a TEM. It was found that a SWCNT nucleated and grew perpendicularly from a region of the catalyst nanoparticle surface, instead of the normal tangential growth that occurs with no sulfur addition. Our in situ TEM observation combined with CVD growth studies suggests that sulfur functions to promote the nucleation and growth of SWCNTs by forming inhomogeneous local active sites and modifying the interface bonding between catalysts and precipitated graphitic layers, so that carbon caps can be lifted off from the catalyst particle.

Ultra-pure single wall carbon nanotube fibres continuously spun without promoter

We report a new strategy towards the control of carbon nanotube (CNT) structure and continuous fibre formation using a floating catalyst direct spinning CVD process. In the procedures used to date, a sulphur promoter precursor is added to significantly enhance the rate of CNT formation in the floating catalyst synthesis. Within the reaction zone, the rapidly grown nanotubes self-assemble into bundles, followed by their continuous spinning into fibres, yarns, films or tapes. In this paper we demonstrate a catalyst control strategy in the floating catalyst system, where the CNT formation process is independent of the presence of a promoter but leads to successful spinning of the macroscopic carbon nanotube assemblies with specific morphology, high purity (Raman D/G 0.03) and very narrow diameter range (0.8-2.5 nm). This can be achieved by the control of catalyst precursor decomposition and subsequent formation of homogeneous nano-sized catalyst particles.

Importance of carbon solubility and wetting properties of nickel nanoparticles for single wall nanotube growth

Optimized growth of single wall carbon nanotubes requires full knowledge of the actual state of the catalyst nanoparticle and its interface with the tube. Using tight binding based atomistic computer simulations, we calculate carbon adsorption isotherms on nanoparticles of nickel, a typical catalyst, and show that carbon solubility increases for smaller nanoparticles that are either molten or surface molten under experimental conditions. Increasing carbon content favors the dewetting of Ni nanoparticles with respect to sp(2) carbon walls, a necessary property to limit catalyst encapsulation and deactivation. Grand canonical Monte Carlo simulations of the growth of tube embryos show that wetting properties of the nanoparticles, controlled by carbon solubility, are of fundamental importance to enable the growth, shedding new light on the growth mechanisms.

Sulphate-activated growth of bamboo-like carbon nanotubes over copper catalysts

A sulphate-activated mechanism is proposed to describe the growth of bamboo-like carbon nanotubes (CNTs) over copper catalysts using chemical vapour deposition with helium-diluted ethylene. Sulphate-assisted copper catalysts afford a high-yield growth of bamboo-like CNTs at a mild temperature, 800 °C; however, non-sulphate-assisted copper catalysts, e.g., copper acetate and copper nitrate prepared catalysts, were inert to CNT growth and only gave amorphous carbons (a-C) surrounding copper nanoparticles under the same conditions. Nevertheless, the addition of sulphate ions in the preparation step for the two inert catalysts can activate their abilities for CNT growth with remarkable yields. Furthermore, Raman spectra analysis demonstrates a linear dependence between the concentration of sulphate ions in copper catalysts and the ratio of CNT-a-C in the as-grown carbon soot. The sulphate-activated effect on CNT growth over copper catalysts could be related to a three-way interaction of sulphate ions, copper nanoparticles and support. In situ TEM images of an as-grown CNT irradiated by electron beams without the inlet of carbon sources reveal a new pathway of carbon diffusion through the bulk of copper nanoparticles and an enlarged inner-wall thickness of the on-site CNT. This carbon diffusion model over copper catalysts can provide new insights into the CNT growth mechanism over non-magnetic metal catalysts.

Size, structure, and helical twist of graphene nanoribbons controlled by confinement in carbon nanotubes

Carbon nanotubes (CNTs) act as efficient nanoreactors, templating the assembly of sulfur-terminated graphene nanoribbons (S-GNRs) with different sizes, structures, and conformations. Spontaneous formation of nanoribbons from small sulfur-containing molecules is efficiently triggered by heat treatment or by an 80 keV electron beam. S-GNRs form readily in CNTs with internal diameters between 1 and 2 nm. Outside of this optimum range, nanotubes narrower than 1 nm do not have sufficient space to accommodate the 2D structure of S-GNRs, while nanotubes wider than 2 nm do not provide efficient confinement for unidirectional S-GNR growth, thus neither can support nanoribbon formation. Theoretical calculations show that the thermodynamic stability of nanoribbons is dependent on the S-GNR edge structure and, to a lesser extent, the width of the nanoribbon. For nanoribbons of similar widths, the polythiaperipolycene-type edges of zigzag S-GNRs are more stable than the polythiophene-type edges of armchair S-GNRs. Both the edge structure and the width define the electronic properties of S-GNRs which can vary widely from metallic to semiconductor to insulator. The encapsulated S-GNRs exhibit diverse dynamic behavior, including rotation, translation, and helical twisting inside the nanotube, which offers a mechanism for control of the electronic properties of the graphene nanoribbon via confinement at the nanoscale.

Recent progress on the growth mechanism of carbon nanotubes: a review

Tremendous progress has been achieved during the past 20 years on not only improving the yields of carbon nanotubes and move progressively towards their mass production, but also on gaining a profound fundamental understanding of the nucleation and the growth processes. Parameters that influence the yield but also the quality (e.g., microstructure, homogeneity within a batch) are better understood. The influence of the carbon precursor, the reaction conditions, the presence of a catalyst, the chemical and physical status of the latter, and other factors have been extensively studied. The purpose of the present Review is not to list all the experiments reported in the literature, but rather to identify trends and provide a comprehensive summary on the role of selected parameters. The role of the catalyst occupies a central place in this Review as a careful control of the metal particle size, particle dispersion on the support, the metastable phase formed under reaction conditions, its possible reconstruction, and faceting strongly influence the diameter of the carbon nanotubes, their structure (number of walls, graphene sheet orientation, chirality), their alignment, and the yield. The identified trends will be compared with recent observations on the growth of graphene. Recent results on metal-free catalysts will be analyzed from a different perspective.

Nanostructures on surfaces of the metalorganic compound {Fe2(CO)6[µ-S2C6H2(OH)2]} and its potential as catalyst precursor for the synthesis of carbon nanotubes

The compound {Fe(2)(CO)(6)[µ-S(2)C(6)H(2)(OH)(2)]} is organized by H-bond interactions on graphite and SiO(2) surfaces as micron-length nanofibres. Thermal degradation of these fibres adsorbed on SiO(2) leads to a very homogeneous surface filled with Fe(2)O(3) nanoparticles (ca. 2.5 nm diameter) suitable to produce few-walled carbon nanotubes laying on a clean surface.