Thermal transport phenomena and limitations in heterogeneous polymer composites containing carbon nanotubes and inorganic nanoparticles

An Off-Lattice Monte Carlo model was developed to investigate effective thermal conductivities (K_eff) and thermal transport limitations of polymer composites containing carbon nanotubes (CNTs) and inorganic nanoparticles. The simulation results agree with experimental data for poly(ether ether ketone) (PEEK) with inclusions of CNTs and tungsten disulfide (WS₂) nanoparticles. The developed model can predict the thermal conductivities of multiphase composite systems more accurately than previous models by taking into account interfacial thermal resistance (R_bd) between the nanofillers and the polymer matrix, and the nanofiller orientation and morphology. The effects of (i) R_bd of CNT–PEEK and WS₂–PEEK (0.0232–115.8 × 10⁻⁸ m²K/W), (ii) CNT concentration (0.1–0.5 wt%), (iii) CNT morphology (aspect ratio of 50–450, and diameter of 2–8 nm), and (iv) CNT orientation (parallel, random and perpendicular to the heat flux) on K_eff of a multi-phase composite are quantified. The simulation results show that K_eff of multiphase composites increases when the CNT concentration increases, and when the R_bd of CNT–PEEK and WS₂–PEEK interfaces decrease. The thermal conductivity of composites with CNTs parallel to the heat flux can be enhanced ∼2.7 times relative to that of composites with randomly-dispersed CNTs. CNTs with larger aspect ratio and smaller diameter can significantly improve the thermal conductivity of a multiphase polymer composite.     

Electromagnetic interference shielding properties of polymer-grafted carbon nanotube composites with high electrical resistance

Poly(methyl methacrylate) (PMMA)-grafted multiwalled CNTs were prepared, and then dispersed into additional PMMA matrix, yielding highly insulated PMMA–CNT composites. The volume resistivity of PMMA–CNT was as high as 1.3 × 10¹⁵ Ω cm even at 7.3 wt% of the CNT. The individual CNTs electrically-isolated by the grafted PMMA chains in PMMA–CNT transmitted electromagnetic (EM) waves in the frequency range of 0.001–1 GHz, whereas the percolated CNTs in a conventional composite prepared by blending PMMA with the pristine CNTs strongly shielded the EM waves. This result suggests that the intrinsic conductivity of the CNT itself in PMMA–CNT does not contribute to the EM interference (EMI) shielding in the frequency range of 0.001–1 GHz. On the other hand, PMMA–CNT exhibited EMI shielding at the higher frequency range than 1 GHz because the dielectric loss of the CNT itself was rapidly increased over 1 GHz. At 110 GHz, PMMA–CNT with 7.3 wt% of the CNT had EMI SE of as high as 29 dB (0.57 mm thickness), though is slightly lower than that of the percolated conventional composite (35 dB). Thus, it is demonstrated that the highly insulated PMMA–CNT has the good EMI shielding at extremely high frequency range (30–300 GHz).     

Overcoming the quality–quantity tradeoff in dispersion and printing of carbon nanotubes by a repetitive dispersion–extraction process

Dispersion-printing processes are essential for the fabrication of various devices using carbon nanotubes (CNTs). Insufficient dispersion results in CNT aggregates, while excessive dispersion results in the shortening of individual CNTs. To overcome this tradeoff, we propose here a repetitive dispersion–extraction process for CNTs. Long-duration ultrasonication (for 100 min) produced an aqueous dispersion of CNTs with sodium dodecylbenzene sulfonate with a high yield of 64%, but with short CNT lengths (a few μm), and poor conductivity in the printed films (∼450 S cm⁻¹). Short-duration ultrasonication (for 3 min) yielded a CNT dispersion with a very small yield of 2.4%, but with long CNTs (up to 20–40 μm), and improved conductivity in the printed films (2200 S cm⁻¹). The remaining sediment was used for the next cycle after the addition of the surfactant solution. 90% of the CNT aggregates were converted into conductive CNT films within 13 cycles (i.e., within 39 min), demonstrating the improved conductivity and reduced energy/time requirements for ultrasonication. CNT lines with conductivities of 1400–2300 S cm⁻¹ without doping and sub-100 μm width, and uniform CNT films with 80% optical transmittance and 50 Ω/sq sheet resistance with nitric acid doping were obtained on polyethylene terephthalate films.     

Growth of carbon nanotube forests between a bi-metallic catalyst layer and a SiO2 substrate to form a self-assembled carbon–metal heterostructure

A special nanostructure was formed by the growth of carbon nanotubes (CNTs) between a substrate and a thin bi-metallic catalyst layer using a thermal chemical vapor deposition process. The catalyst layer is composed of adjacently disposed Cr and Ni phases formed prior to CNT growth. The Cr/Ni layer serves as a bi-metallic catalyst layer, which is pushed away from the substrate as a thin and continuous nanomembrane with the growth of CNTs. The self-assembled CNT–catalyst heterostructure possesses a smooth surface (RMS = 2.9 nm) with a metallic shine. Directly interlinked to the Cr/Ni layer, dense and vertically aligned multi-walled CNTs are found. Compared to conventional CNT films, the structure has significant advantages for CNT integration. From technology point of view, the structure allows further processing without impact on the CNTs as well as transfer of pristine vertically aligned CNTs to arbitrary substrates. Moreover, the as-grown CNT films provide an interface ideal for further electrical, thermal and mechanical contacting of CNT films. We present structural investigations of this special CNT–metal heterostructure. Furthermore, we discuss possible interface mechanisms during catalyst layer formation and CNT growth.     

Multifunctional bioceramic-based composites reinforced with silica-coated carbon nanotube core-shell structures

Carbon nanotube (CNT) possesses eminent mechanical properties and has been widely utilized to toughen bioceramics. Major challenges associated with CNT-reinforced bioceramics include the inhomogeneous dispersion of CNTs and the insufficient interfacial strength between the two phases. To address such issues, this research describes the first use of silica-coated CNT (S-CNT) core-shell structures to reinforce bioceramics using hydroxyapatite (HA) as a representative matrix. HA-based composites with 0.1–2 wt% S-CNT are sintered by spark plasma sintering to investigate their mechanical and biological properties. It is found that when 1 wt% raw CNT (R-CNT) is added, very limited increases in fracture toughness (K_IC) is observed. By contrast, the incorporation of 1 wt% S-CNT increased the K_IC of HA by 101.7%. This is attributed to more homogeneously dispersed fillers and stronger interfacial strengths. MG63 cells cultured on the 1 wt% S-CNT/HA pellets are found to proliferate faster and possess significantly higher alkaline phosphatase activities than those grown on the HA compacts reinforced with 1 wt% R-CNT, probably by virtue of the released Si ions from the SiO2 shell. Therefore, the S-CNT core-shell structures can improve both mechanical and biological properties of HA more effectively than the conventionally used R-CNTs. The current study also presents a novel and effective approach to the enhancement of many other biomedical and structural materials through S-CNT incorporation.     

Enhanced field emission properties from titanium-coated carbon nanotubes

The effect of titanium (Ti) coating over the surface of carbon nanotubes (CNTs) on field emission characteristics was investigated. Vertically aligned CNTs were grown by inductively-coupled plasma-enhanced chemical vapor deposition (ICP-CVD). In order to reduce the screening effect of electric field due to densely packed CNTs, as-grown CNTs were partly etched back by DC plasma of N₂. Ti with various thicknesses from 5 nm to 150 nm was coated on CNTs by a sputtering method. Since thick Ti coating with thickness of 100 nm or more resulted in the shape of a metal post by merging an individual CNT in a bundle, it was inadequate to a field emission application. On the other hand, thin Ti-coated CNTs with thickness of 10 nm or less showed a lower turn-on field, a higher emission current density, and improved emission uniformity compared with pristine CNTs. The improved emission performance was mainly attributed to the low work function of Ti and the reliable and lower resistance contact between CNTs and substrates.     

Development of high oxidation resistant coating of nanostructured MgO on carbon nanotubes via simple precipitation technique in Mg/CO gas system

The synthesis of oxide-coated carbon nanotubes (CNTs) by a simple precipitation reaction in Mg/CO gaseous system was studied. The results showed that nanostructured MgO could be uniformly coated on the surface of CNTs via inhomogeneous Mg_(g) and CO_(g) precipitation reaction. Furthermore, we have developed a mixing procedure based on simultaneous agitation and ultra-sonication in order to break CNT bundles and prepare highly dispersed starting materials. By applying such mixing procedure, dispersed and distinct nano-oxide coated CNTs were synthesized which can be efficiently utilized in different composite matrices. Oxidation resistance of samples was investigated by DSC/TG thermal analysis. The results showed that oxide-coated CNTs present superior resistance against oxidation even at rather elevated temperature of 1000 °C and total weight loss of coated CNTs was measured to be less than 1 wt% during heat treatment at such temperature. Finally, coating adhesion was evaluated employing ultrasonic waves (as mechanical force) and subsequent weight loss measurement at temperature of 1000 °C.     

On the manufacturing and electrical and mechanical properties of ultra-high wt.% fraction aligned MWCNT and randomly oriented CNT epoxy composites

The effect of CNT orientation on electrical and mechanical properties is presented on the example of an ultra-high filler loaded multi-walled carbon nanotube (68 wt.% MWCNTs) epoxy-based nanocomposite. A novel manufacturing method based on hot-press infiltration through a semi-permeable membrane allows to obtain both, nanocomposites with aligned and randomly oriented CNTs (APNCs and RPNCs) over a broad filler loading range of ≈10–68 wt.%. APNCs are based on low-defected, mm-long aligned MWCNT arrays grown in chemical vapour deposition (CVD) process. Electrical conductivity and mechanical properties were measured parallel and perpendicular to the direction of CNTs. RPNCs are based on both, aligned mm-long MWCNTs and randomly oriented commercial μm-long and entangled MWCNTs (Baytube C150P, and exemplarily Arkema Graphistrength C100). The piezoresistive strain sensing capability of these high-wt.% APNCs and RPNCs had been investigated towards the influence of CNT orientations. For the highest CNT fraction of 68 wt.% of unidirectional aligned CNTs a Young’s modulus of E_|| ≈ 36 GPa and maximum electrical conductivity of σ_|| ≈ 37·10⁴ S/m were achieved.     

Electromagnetic wave absorption properties of graphene modified with carbon nanotube/poly(dimethyl siloxane) composites

By using a catalytic growth procedure, carbon nanotubes (CNTs) are in situ formed on reduced graphene oxide (RGO) sheet at 600 °C. CNTs growing on RGO planes through covalent C–C bond possess lower interfacial contact electrical resistance. As a hybrid structure, the CNTs/graphene (CNT/G) are well dispersed into poly (dimethyl siloxane). The hybrid combining electrically lossy CNTs and RGO, which disperses in electrically insulating matrix, constructs an electromagnetic wave (EM) absorbing material with ternary hierarchical architecture. The interfacial polarization in heterogeneous interface plays an important role in absorbing EM power. When the filler loading is 5 wt.% and thickness of absorber is 2.75 mm, the minimum value of reflection coefficient and the corresponding frequency are −55 dB and 10.1 GHz, and the effective absorption bandwidth reaches 3.5 GHz. Therefore, combining the CNTs and graphene sheet into three-dimensional structures produces CNT/G hybrids that can be considered as an effective route to design light weight and high-performance EM absorbing material, while the effective EM absorption frequency can be designed.     

Hydrogen-storage properties of MgH2–10Ni–2NaAlH4–2Ti–2CNT milled in a planetary ball mill under H2

A sample with a composition of 84 wt% MgH₂–10 wt% Ni–2 wt% NaAlH₄–2 wt% Ti–2 wt% CNT (named MgH₂–10Ni–2NaAlH₄–2Ti–2CNT) was prepared by milling in a planetary ball mill under H₂. Activation of the sample was not required. At the first cycle, the sample absorbed 3.75 wt% H for 10 min, and 4.17 wt% H for 60 min at 593 K under 12 bar H₂. Reactive mechanical grinding of Mg with Ni, NaAlH₄, Ti, and CNT is thought to create defects on the surface and in the interior of Mg, as well as to reduce Mg particle size.     

Preparation-microstructure-property relationships in double-walled carbon nanotubes/alumina composites

Double-walled carbon nanotube/alumina composite powders with low carbon contents (2–3 wt.%) are prepared using three different methods and densified by spark plasma sintering. The mechanical properties and electrical conductivity are investigated and correlated with the microstructure of the dense materials. Samples prepared by in situ synthesis of carbon nanotubes (CNTs) in impregnated submicronic alumina are highly homogeneous and present the higher electrical conductivity (2.2–3.5 S cm⁻¹) but carbon films at grain boundaries induce a poor cohesion of the materials. Composites prepared by mixing using moderate sonication of as-prepared double-walled CNTs and lyophilisation, with little damage to the CNTs, have a fracture strength higher (+30%) and a fracture toughness similar (5.6 vs 5.4   MPa m^1/2) to alumina with a similar submicronic grain size. This is correlated with crack-bridging by CNTs on a large scale, despite a lack of homogeneity of the CNT distribution.     

Polyimide/nano-TiO2 hybrid films having benzoxazole pendent groups: In situ sol–gel preparation and evaluation of properties

Polyimide/titania (PI/TiO₂) nanocomposite films have been successfully fabricated through the in situ formation of TiO₂ within a PI matrix via sol–gel method. Poly(amic acid) (PAA), which is the precursor of PI, was successfully synthesized by mixing pyromellitic dianhydride (PMDA), with equimolar amount of a diamine monomer having a pendent benzoxazole unit and two flexible ether linkages in N,N-dimethylformamide (DMF) solvent. Tetraethyl orthotitanate [Ti(OEt)₄] and acetylacetone were then added to the resulted PAA. After imidization at high temperature, PI/TiO₂ hybrid films were formed. The structure and morphology of the hybrid nanocomposites with different titania contents (0 wt%, 5 wt%, 10 wt%, and 15 wt%) were characterized by Fourier transform infrared spectroscopy, X-ray diffraction, and transmission electron microscopy. The results indicate that the TiO₂ nanoparticles were homogeneously dispersed in the hybrid films. The thermogravimetric analysis of nanocomposites confirms the improvement in the thermal stability with the increase in the percentage of titania nanoparticle. Transmission electron microscopy showed that the nanoparticles with an average diameter of 25–40 nm were dispersed in the polymer matrix.     

Pressureless sintering of carbon nanotube–Al2O3 composites

Alumina ceramics reinforced with 1, 3, or 5 vol.% multi-walled carbon nanotubes (CNTs) were densified by pressureless sintering. Commercial CNTs were purified by acid treatment and then dispersed in water at pH 12. The dispersed CNTs were mixed with Al₂O₃ powder, which was also dispersed in water at pH 12. The mixture was freeze dried to prevent segregation by differential sedimentation during solvent evaporation. Cylindrical pellets were formed by uniaxial pressing and then densified by heating in flowing argon. The resulting pellets had relative densities as high as ～99% after sintering at 1500 °C for 2 h. Higher temperatures or longer times resulted in lower densities and weight loss due to degradation of the CNTs by reaction with the Al₂O₃. A CNT/Al₂O₃ composite containing 1 vol.% CNT had a higher flexure strength (～540 MPa) than pure Al₂O₃ densified under similar conditions (～400 MPa). Improved fracture toughness of CNT–Al₂O₃ composites was attributed to CNT pullout. This study has shown, for the first time, that CNT/Al₂O₃ composites can be densified by pressureless sintering without damage to the CNTs.     

Mechanical and electrical properties of carbon nanotube buckypaper reinforced silicon carbide nanocomposites

The nanocomposite was produced via phenolic resin infiltrating into a carbon nanotube (CNT) buckypaper preform containing B₄C fillers and amorphous Si particles followed by an in-situ reaction between resin-derived carbon and Si to form SiC matrix. The buckypaper preform combined with the in-situ reaction avoided the phase segregation and increased significantly the volume fraction of CNTs. The nanocomposites prepared by this new process were dense with the open porosities less than 6%. A suitable CNT–SiC bonding was achieved by creating a B₄C modified interphase layer between CNTs and SiC. The hardness increased from 2.83 to 8.58 GPa, and the indentation fracture toughness was estimated to increase from 2.80 to 9.96 MPa m^1/2, respectively, by the reinforcing effect of B₄C. These nanocomposites became much more electrically conductive with high loading level of CNTs. The in-plane electrical resistivity decreased from 124 to 74.4 μΩ m by introducing B₄C fillers.     

Interplay between exchange interaction and magnetic anisotropy for iron based nanoparticles in aligned carbon nanotube arrays

In this work, we investigate magnetic properties of iron based nanoparticles (NP) intercalated into carbon nanotube (CNT) aligned arrays synthesized by injection chemical vapor deposition. We have analyzed the temperature (T) and the ferrocene concentration (C_F) dependences of the macroscopic magnetic parameters. From these experiments a weaker interaction between magnetic moments of NP was obtained for low C_F values. The random anisotropy model for the experimental data analysis was applied and micromagnetic parameters were evaluated. The law of the approach to magnetic saturation (LAS) was analyzed using the general expression with the correlation function C(r = x/R_a) of magnetic axes, R_a being the magnetic anisotropy correlation length. We obtained that, while for C_F = 0.5% C(r) is a step-like (C(r < 10) = 1, C(r > 10) = 0), for C_F ⩾ 1% C(r) decays rapidly on a short range, (2-3)R_a. Such extended correlations for C_F = 0.5% could be associated with the dominant role of the coherent anisotropy, which is caused by the influence of the alignment of CNT. When the aligned CNTs for C_F = 0.5% are destroyed into powder, the LAS is changed to H^−1/2, which means the dominant role of the exchange mechanism.     

Carbon nanotube and nanofiber syntheses by the decomposition of methane on group 8–10 metal-loaded MgO catalysts

We have found that several precious metal-loaded MgO catalysts are active in the formation of carbon nanotube (CNT) by the chemical vapor deposition (CVD) of methane. The catalysts were prepared with nine metals (Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, and Pt) by impregnation onto a high surface area MgO. CNT synthesis was carried out in the temperature range from 600 °C to 1000 °C after reduction with H₂ at 800 °C.The amount of carbon deposited and crystallinity in the produced CNT on nine metals showed interesting tendencies: (i) The amount of carbon formed increased in the following transition series metals: first < second < third row transition elements, and (ii) the index of crystallinity I_G/I_D in Raman-bands of the CNTs decreased in the following order: 8 > 9 > 10 in the Periodic Table. Group 8 and 9 metals produced tube type fibers composed of the graphite layers arranged parallel to the fiber axis. On the other hand, carbon nanofibers (CNFs) grown on group 10 metals had herringbone type graphene sheets.     

Improvement of textured Bi1.6Pb0.4Sr2Co1.8Ox thermoelectric performances by metallic Ag additions

Bi_1.6Pb_0.4Sr₂Co_1.8O_x thermoelectric ceramics with small Ag additions (0, 1, and 3 wt%) have been successfully grown from the melt, using the laser floating zone method. Microstructure has shown a reduction in the amount of secondary phases and a better grain alignment with respect to the growth direction for an Ag content of 3 wt%. The microstructural evolution, as a function of Ag content, is confirmed with the electrical resistivity values, which show an important decrease for the 3 wt% Ag samples, leading to maximum power factor values of about 0.42 mW/K² m at 650 °C, which are among the best results obtained in this type of material.     

The influence of CNTs on the thermoelectric properties of a CNT/Bi2Te3 composite

CNT/Bi₂Te₃ composites were prepared from composite powders in which CNTs were implanted in the Bi₂Te₃ matrix powders by a novel chemical route. It was found that the fabricated composite had a microstructure of a homogeneous dispersion of CNTs in the Bi₂Te₃ matrix due to interfacial bonding agents of oxygen atoms attaching to the surface of CNTs. The dimensionless figure of merit (ZT) of the composite shows significantly increased values compared to those of pure binary Bi₂Te₃ in the temperature range of 298–498 K and a maximum ZT of 0.85 was obtained at 473 K. It is considered that the improved thermoelectric performance of the composite mainly originated from thermal conductivity that was reduced by active phonon-scattering at the CNT/Bi₂Te₃ interface.     

Improved thermal interface property of carbon nanotube–Cu composite based on supercritical fluid deposition

In this paper, we present a new synthesis method of carbon nanotubes (CNTs)-copper (Cu) composite on a silicon substrate using combination of supercritical fluid deposition (SCFD) and electrochemical plating (ECP) process. Deposition of a Cu layer onto CNTs is carried out under supercritical condition, and the CNTs–Cu composite with high-density Cu is synthesized by additional ECP process. The Cu layer deposited by SCFD functions as a seed layer for ECP, and spaces between neighboring CNTs are filled by Cu. The measured density of the CNTs–Cu composite is 8.2 ± 0.3 g/cm³, and the volume percentage of voids is 3–6%. The evaluated thermal resistance including the thermal interface resistance and bulk resistance of the composite is as low as 28.4 mm² K W⁻¹ at a contact pressure of 0.2 MPa. A CNT brush formed on the composite surface can reduce the thermal resistance to be 68.4 mm² K W⁻¹ at a contact pressure of 0.25 MPa. The CNTs–Cu composite shows the ability applicable to many microelectronics applications as a thermal interface material.     

Fabrication and toughening behavior of carbon nanotube (CNT) scaffold reinforced SiBCN ceramic composites with high CNT loading

Uniform dispersion, high loading and three-dimensional (3D) continuous network of carbon nanotube (CNT) are desired for high-performance nanocomposites to fully utilize the superior strength and toughness of CNTs. In this work, monolithic CNTs/SiBCN composites with high CNT loading (10 wt% and 20 wt%) were prepared from 3D scaffold-like CNT cottons and a liquid polyborosilazane (PBSZ) precursor through precursor infiltration and pyrolysis process. The 3D CNT scaffold in the nanocomposite can function as passive filler and gas path to ensure formation of monolithic bulks. Moreover, direct infiltration of PBSZ into the pores among CNT cotton can hinder agglomeration of CNTs and localize CNTs at the original sites, guarantee good alignment and high CNT concentration in the final nanocomposite. This highly concentrated 3D CNT reinforcement in the nanocomposite shows unique resistance to cracking under external stress related to the complex fracture behavior of CNT bundles during the cracking formation and extension process (including CNT bridging, aligning, pulling out and then breaking), which more favors for absorbing energies and enhance toughness of the ceramic composites.