Growth of carbon nanofibers on activated carbon fiber fabrics

Activated carbon fiber fabrics, an excellent adsorbent, were used as catalyst supports to grow carbon nanofibers. Because of the microporous structure of the activated carbon fibers, the catalysts could be distributed uniformly on the carbon surface. Based on this concept, the carbon nanofibers can be grown directly on the activated carbon fiber fabrics. We demonstrate that carbon nanofibers with a diameter between 20 and 50 nm for most of the fibers can be synthesized uniformly and densely on activated carbon fiber fabrics, impregnated by nickel nitrate catalyst precursor, using catalytic chemical vapor deposition. Although the carbon nanofibers are not straight with a crooked morphology, they form a three-dimensional network structure. Structure characterizations by TEM and XRD indicate that the carbon nanofibers have a turbostratic graphite structure and the graphite layers are stacked with a herringbone structure.     

Chemical vapor-deposited carbon nanofibers on carbon fabric for supercapacitor electrode applications

Entangled carbon nanofibers (CNFs) were synthesized on a flexible carbon fabric (CF) via water-assisted chemical vapor deposition at 800°C at atmospheric pressure utilizing iron (Fe) nanoparticles as catalysts, ethylene (C₂H₄) as the precursor gas, and argon (Ar) and hydrogen (H₂) as the carrier gases. Scanning electron microscopy, transmission electron microscopy, and electron dispersive spectroscopy were employed to characterize the morphology and structure of the CNFs. It has been found that the catalyst (Fe) thickness affected the morphology of the CNFs on the CF, resulting in different capacitive behaviors of the CNF/CF electrodes. Two different Fe thicknesses (5 and 10 nm) were studied. The capacitance behaviors of the CNF/CF electrodes were evaluated by cyclic voltammetry measurements. The highest specific capacitance, approximately 140 F g⁻¹, has been obtained in the electrode grown with the 5-nm thickness of Fe. Samples with both Fe thicknesses showed good cycling performance over 2,000 cycles.     

Enhancement of electrosorption capacity of activated carbon fibers by grafting with carbon nanofibers

The composite films of activated carbon fibers (ACFs) and carbon nanofibers (CNFs) are prepared via chemical vapor deposition of CNFs onto ACFs in different times from 0.5 to 2 h and their electrosorption behaviors in NaCl solution are investigated. The morphology, structure, porous and electrochemical properties are characterized by scanning electron microscopy, transmission electron microscopy, Raman spectroscopy, N₂ adsorption at 77 K, contact angle goniometer and electrochemical workstation, respectively. The results show that CNFs have been hierarchically grown on the surface of ACFs and the as grown ACF/CNF composite films have less defects, higher specific capacitances, more suitable mesoporous structure and more hydrophilic surface than the pristine ACFs, which is beneficial to their electrosorption performance. The ACFs/CNFs with CNFs deposited in 1 h exhibit an optimized NaCl removal ratio of 80%, 55% higher than that of ACFs and the NaCl electrosorption follows a Langmuir isotherm with a maximum electrosorption capacity of 17.19 mg/g.     

Controlling the yield and structure of carbon nanofibers grown on a nickel/activated carbon catalyst

Carbon nanofibers (CNFs) were grown via the chemical vapor deposition of C₂H₄ on an activated carbon (AC)-supported Ni catalyst. The texture of the CNF/AC composites can be tuned by varying the growth temperature and by treatment in reducing atmosphere prior to C₂H₄/H₂ exposure. The Ni-catalyzed gasification of the AC support increases the microporosity of the composite and shown to be dominant throughout the composite synthesis especially during reduction, subsequent treatment in reducing atmosphere, and CNF growth at low temperatures. N₂ isotherm and scanning electron microscope were used to characterize the texture and morphology of the composites. Subsequent treatment in reducing atmosphere were shown to increase the Ni catalyst activity to grow CNFs. High resolution transmission electron microscope however did not reveal any microstructural difference for Ni catalyst with and without the subsequent reduction treatment. We propose in this paper that the carbon dissolutions during treatment of the catalyst might have an implication on the CNF growth.     

Carbon nanotubes filled with metallic nanowires

A facile method is proposed to use LaNi₂ hydrogen storage alloy as a catalyst precursor to produce metallic nickel filled carbon nanotubes. Multi-walled carbon nanotubes filled with long continuous nickel nanowire with several microns in length are synthesized through chemical vapor deposition at low temperature (550 °C). It is more efficient to fill Ni nanowires into nanotubes after the oxidation treatment of LaNi₂ alloy at low temperatures, while the oxidation treatment at high temperature results in the forming of herringbone carbon nanofibers with tips of Ni nanoparticles. The metallic Ni nanowires inside the cores of carbon nanotubes could not be eliminated during the purification process in concentrated hydrochloric acid. The analysis of transmission electron microscopy (TEM), selected area electron diffraction (SAED) and X-ray diffraction (XRD) reveals that the metallic nickel nanowires filled inside carbon nanotubes exist as a single crystalline with fcc structure.     

Radio-frequency plasma system to selectively grow vertical field-aligned carbon nanofibers from a solid carbon source

Vertical field-aligned carbon nanofibers (CNFs), exhibiting a “herring-bone” and a “bamboo-like” structure, were grown at 560 °C using nickel (Ni) as a catalyst and an innovative radio-frequency (RF) plasma-enhanced chemical vapor deposition system. To limit the carbon supply, thereby providing a highly selective growth process with no detrimental parasitic carbon layer formation, a solid graphite sample-holder, RF-polarized, was used as a single carbon source in combination with a pure H₂ feed gas. The morphology and the dimensions of the obtained CNFs are investigated with respect to the growth duration. High-resolution transmission electron microscopy analyses typically display a Ni particle at the fiber tip, but this particle is not encapsulated by graphene layers, allowing its easy removal with a chemical acid treatment. Moreover, the particle’s upper surface consists of a peculiar polycrystalline area, assumed to be essential for the growth mechanisms and possibly made of nickel carbide. The crucial role played by the average vertical electric field, naturally created in the plasma sheath and responsible for sample-holder and substrate bombardment by cationic species, is highlighted to understand the growth mechanisms of these as-grown oriented CNFs and their progressive base destruction by etching phenomena.     

Mechanistic study of cobalt catalyzed growth of carbon nanofibers in a confined space by plasma-assisted chemical vapor deposition

Carbon nanofibers (CNFs) were grown in the porous anodic aluminum oxide (AAO) thin film grown on the Si wafer by electron cyclotron resonance chemical vapor deposition using cobalt as the catalyst. A larger Co particle electrodeposited in the AAO pore channel produced vertically aligned CNFs with a tube diameter in compliance with the pore size of the AAO template. On the other hand, a smaller Co particle resulted in CNF growth with a nonuniform distribution of the tube diameter and a sparse tube density. Amorphous carbon residue produced under the plasma-assisted CNF growth condition seemed to play an essential role leading to the observation. A growth mechanism is proposed to delineate the volume effect of the electrodeposited Co catalyst on the CNF growth confined in pore channels of the AAO template.     

Electromechanical analysis of single-walled carbon nanotubes suspended across carbon nanofiber templates using scanning electron microscopy

A real-time and non-contact method using scanning electron microscopy is demonstrated for the electromechanical analysis of suspended single-walled carbon nanotubes (su-SWCNTs) to estimate the adhesive force to the supporting templates. The su-SWCNTs were directly synthesized across vertically-aligned carbon nanofibers (CNFs) with size-reduced catalytic nanoparticles encapsulated at the tips using a special three-step process. Results from the measurements and an analysis by a simplified model, valid for a large deflection regime, reveal a strong non-van der Waals force interaction at the interface. The strong adhesive force observed can be attributed to strong chemical bonds at the SWCNT-CNF junctions and amorphous carbon layers clamping around the tips of the CNFs, both formed during the high temperature catalytic chemical vapor deposition process for SWCNT synthesis. The strong adhesion between the SWCNTs and the supporting templates is highly desirable for the fabrication of reliable SWCNT-based electromechanical devices.     

Palladium catalyzed formation of carbon nanofibers by plasma enhanced chemical vapor deposition

A dc plasma enhanced chemical vapor deposition process is used to obtain vertically aligned carbon nanofibers (CNFs) from palladium catalysts using an ammonia-acetylene process gas mixture. Transmission electron microscopy is used to elucidate the microstructure of the as-grown fibers revealing different growth anomalies such as a new secondary growth phenomenon which we term hybrid tip growth. Also included in our analysis are conventional tip growth derived structures. In a few instances, the conventional tip growth derived structures possess elongated catalyst particles that impart small cone angles to the carbon nanofiber microstructure. Detailed microchemical analysis reveals that hybrid tip grown CNFs using thick Pd films are partially filled with Pd. Analysis of these growth phenomenon and implications for potential use as on-chip interconnects are discussed.     

Low temperature growth mechanisms of vertically aligned carbon nanofibers and nanotubes by radio frequency-plasma enhanced chemical vapor deposition

Using radio frequency-plasma enhanced chemical vapor deposition (RF-PECVD), carbon nanofibers (CNFs) and carbon nanotubes (CNTs) were synthesized at low temperature. Base growth vertical turbostratic CNFs were grown using a sputtered 8 nm Ni thin film catalyst on Si substrates at 140 °C. Tip growth vertical platelet nanofibers were grown using a Ni nanocatalyst in 8 nm Ni films on TiN/Si at 180 °C. Using a Ni catalyst on glass substrate at 180 °C a transformation of the structure from CNFs to CNTs was observed. By adding hydrogen, tip growth vertical multi-walled carbon nanotubes were produced at 180 °C using FeNi nanocatalyst in 8 nm FeNi films on glass substrates. Compared to the most widely used thermal CVD method, in which the synthesis temperature was 400–850 °C, RF-PECVD had a huge advantage in low temperature growth and control of other deposition parameters. Despite significant progress in CNT synthesis by PECVD, the low temperature growth mechanisms are not clearly understood. Here, low temperature growth mechanisms of CNFs and CNTs in RF-PECVD are discussed based on plasma physics and chemistry, catalyst, substrate characteristics, temperature, and type of gas.     

Robust growth of herringbone carbon nanofibers on layered double hydroxide derived catalysts and their applications as anodes for Li-ion batteries

Herringbone carbon nanofibers (CNFs) were efficiently produced by chemical vapor deposition on Ni nanoparticles derived from layered double hydroxide (LDH) precursors. The as-obtained CNFs with a diameter ranging from 40 to 60 nm demonstrated herringbone morphologies when they grew on Ni/Al LDH derived catalysts both in the fixed-bed and fluidized-bed reactor. The Ni/Mg/Al, Ni/Cu/Al, as well as Ni/Mo/Mg/Al catalysts were also effective to grow herringbone CNFs. The diameter and specific surface area of the as-obtained CNFs highly depended on the catalyst composition and the growth temperature. When CNFs were grown at 550 °C on Ni/Al catalyst, the as-obtained products had an outer diameter of ca. 50 nm and a specific surface area of 242 m² g⁻¹, possessed a discharge capacity of 330 mAh g⁻¹ as the electrode in a two-electrode coin-type cell. With the increase of the surface area, the discharge capacity increased at a rate of 0.90 mAh cm⁻², while the initial coulombic efficiency decreased gradually on nanocarbon anodes. This is attributed to the fact that CNFs with higher surface area afford smaller sp² carbon layer that facilitated more Li ions to extract from the anodes.     

螺线型碳纳米纤维基整体式催化剂活性载体

本工作采用一种简便的一步化学气相沉积(chemical vapor deposition, CVD)法，在泡沫镍基底上直接生长螺线形碳纳米纤维（CNFs/NF）作为对析氧反应有活性的整体式催化剂载体。在1 mol/L KOH为电解质溶液的三电极电解池中，与 CNFs/NF电极材料电化学表面积(ECSA)成正比的的双层电容Cdl值达到13.69 mF/cm2。通过循环伏安法，电化学阻抗谱和线性扫描伏安曲线等电化学手段，验证了CNFs/NF适于做具有析氧反应活性的催化剂载体。CNFs/NF需要260 mV，385 mV的析氧反应过电势以实现10 mA/cm2和100 mA/cm2的电流密度。     

螺线型碳纳米纤维基整体式催化剂活性载体

本工作采用一种简便的一步化学气相沉积(chemical vapor deposition, CVD)法，在泡沫镍基底上直接生长螺线形碳纳米纤维（CNFs/NF）作为对析氧反应有活性的整体式催化剂载体。在1 mol/L KOH为电解质溶液的三电极电解池中，与 CNFs/NF电极材料电化学表面积(ECSA)成正比的的双层电容Cdl值达到13.69 mF/cm2。通过循环伏安法，电化学阻抗谱和线性扫描伏安曲线等电化学手段，验证了CNFs/NF适于做具有析氧反应活性的催化剂载体。CNFs/NF需要260 mV，385 mV的析氧反应过电势以实现10 mA/cm2和100 mA/cm2的电流密度。     

Super growth of vertically-aligned carbon nanofibers and their field emission properties

We demonstrate a very efficient synthesis of vertically-aligned ultra-long carbon nanofibers (CNFs) with sharp tip ends using thermal chemical vapor deposition. Millimeter-scale CNFs with a diameter of less than 50 nm are readily grown on palladium thin film deposited Al₂O₃ substrate, which activate the conical stacking of graphitic platelets. The field emission performance of the as-grown CNFs is better than that of previous CNFs due to their extremely high aspect ratio and sharp tip angle. The CNF array gives the turn-on electric field of 0.9 V/μm, the maximum emission current density of 6.3 mA/cm² at 2 V/μm, and the field enhancement factor of 2585.     

The beneficial effect of CO2 in the low temperature synthesis of high quality carbon nanofibers and thin multiwalled carbon nanotubes from CH4 over Ni catalysts

A low temperature chemical vapor deposition method is described for converting CH₄ into high-quality carbon nanofibers (CNFs) using a Ni catalyst supported on either spinel or perovskite oxides in the presence of CO₂. The addition of CO₂ has a significant influence on CNF purity and stability, while the CNF diameter distribution is significantly narrowed. Ultimately, the addition of CO₂ changes the CNF structure from fishbone fibers to thin multiwalled carbon nanotubes. A new “in situ” cooling principle taking into account dry reforming chemistry and thermodynamics is introduced to account for the structural effects of CO₂.     

Precursor gas chemistry determines the crystallinity of carbon nanotubes synthesized at low temperature

Despite significant progress in carbon nanotube (CNT) synthesis by thermal chemical vapor deposition (CVD), the factors determining the structure of the resulting carbon filaments and other graphitic nanocarbons are not well understood. Here, we demonstrate that gas chemistry influences the crystal structure of carbon filaments grown at low temperatures (500 °C). Using thermal CVD, we decoupled the thermal treatment of the gaseous precursors (C₂H₄/H₂/Ar) and the substrate-supported catalyst. Varying the preheating temperature of the feedstock gas, we observed a striking transition between amorphous carbon nanofibers (CNFs) and crystalline CNTs. These results were confirmed using both a hot-wall CVD system and a cold-wall CVD reactor. Analysis of the exhaust gases (by ex situ gas chromatography) showed increasing concentrations of specific volatile organic compounds (VOCs) and polycyclic aromatic hydrocarbons (PAHs) that correlated with the structural transition observed (characterized using high-resolution transmission electron microscopy). This suggests that the crystallinity of carbon filaments may be controlled by the presence of specific gas phase precursor molecules (e.g., VOCs and PAHs). Thus, direct delivery of these molecules in the CVD process may enable selective CNF or CNT formation at low substrate temperatures. The inherent scalability of this approach could impact many promising applications, especially in the electronics industry.     

Growth of mechanically fixed and isolated vertically aligned carbon nanotubes and nanofibers by DC plasma-enhanced hot filament chemical vapor deposition

Vertically aligned, mechanically isolated, multiwalled carbon nanotubes (MWCNTs) and nanofibers (MWCNFs) were grown using an array of catalyst nickel nanowires embedded in an anodic aluminum oxide (AAO) nanopore template using DC plasma-enhanced hot filament chemical vapor deposition (HFCVD). The nickel nanowire array, prepared by electrodeposition of nickel into the pores of a commercially available AAO membrane, acts as a template for CNT and CNF growth. It also provides both a mechanical “fixed support” boundary condition and enforces sufficient spatial separation of the CNT/CNFs from each other to enable reliable and well-controlled mechanical testing of individual vertically aligned CNT/CNFs. In contrast with other AAO-templated growth methods, no post-growth etching of the AAO is required, since the CNTs/CNFs grow out of the pores and remain vertically aligned. A mixture of hydrogen and methane was used for the growth, with hydrogen acting as a dilution and source gas for the DC plasma, and methane as the carbon source. A negative bias was applied to the sample mount to generate the DC plasma. The filaments provided the necessary heat for dissociation of molecular species, and also heat the sample itself significantly. Both of these effects assist the CNT/CNF growth. Minimal heating came from the low-power plasma. However, the associated DC field was essential for the vertical alignment of the CNTs and CNFs. Scanning electron, transmission electron, and atomic force microscopy confirm that the CNT/CNFs are composed of graphitic layers, and form a vertically aligned, relatively uniform, and dense array across the AAO template. A significant number of the structures grown are indeed high quality nanotubes, as opposed to more defective nanofibers that are often predominant in other growth methods. This method has the advantage of being scalable and consuming less power than other techniques that grow vertically aligned CNTs/CNFs.     

Carbon nanotubes and carbon nanofibers fabricated on tubular porous Al2O3 substrates

Carbon nanotubes and carbon nanofibers were grown at different temperatures on porous ceramic Al₂O₃ substrates with single channel geometry by means of a chemical vapor deposition technique using methane as carbon source and palladium as catalyst. Time-resolved in-situ Fourier transformed infrared spectroscopy was used for the investigation of methane decomposition for characterizing the catalyst’s performance. With increasing synthesis temperature, a structural transition from carbon nanofibers to carbon nanotubes was observed. At a synthesis temperature of 700 °C, solely carbon nanofibers were found, whereas at 800 °C a mixture of two types of bamboo-shaped carbon nanofibers were obtained, suggesting a structural transition. A synthesis temperature to 850 °C results in bamboo-shaped multi-walled carbon nanofibers and multi-walled carbon nanotubes. The carbon products and the observed structural transition were characterized by means of field emission scanning electron microscopy, high-resolution transmission electron microscopy, thermal gravimetric analysis, and Raman spectroscopy.     

Transmission electron microscopy study of the microstructure of carbon/carbon composites reinforced with in situ grown carbon nanofibers

Introduction of carbon nanofibers (CNFs) into carbon/carbon (C/C) composites is an effective method to improve the mechanical properties of C/C composites. In situ grown CNFs reinforced C/C composites as well as conventional C/C composites without CNFs were fabricated by chemical vapor infiltration. Transmission electron microscopy investigations indicate that the entangled CNFs (30–120 nm) formed interlocking networks on the surface of carbon fibers (CFs). Moreover, a thin high-textured (HT) pyrocarbon (PyC) layer (～20 nm) was deposited on the surface of CFs during the growth of CNFs. We find the microstructure of C/C composites depends strongly on the local distribution density (LDD) of CNFs. In regions of low CNF LDD, a triple-layer structure was formed. The inner layer (attached to CF) is HT PyC (～20 nm), the middle layer (150–200 nm) is composed of HT PyC coated CNFs (HT/CNFs) and medium-textured PyC, and the outmost layer (several microns) is composed of HT/CNFs and micropores. In regions of high CNF LDD, a double-layer structure was formed. The inner layer is HT PyC (～20 nm), and the outer layer is composed of HT/CNFs, isotropic PyC and nanopores. However, only medium-textured PyC and micropores were found in the matrix of the conventional C/C composites.     

Enhancement of electron field emission from carbon nanofiber bundles separately grown on Ni catalyst in Ni-Cr alloy

The enhancement of electron field emission was successfully obtained from carbon nanofiber (CNF) bundles separately grown on Ni grains in Ni-Cr alloy compared with that from CNF bundles on pure nickel. Ni grains less than 1 μm in size were separated by Cr grains in the alloy prepared by cosputtering with Ni pellets on a Cr plate without a lithographic patterning process. CNFs grew on Ni grains as bundles of 100 nm diameter and 1 μm length by helicon wave plasma-enhanced chemical vapor deposition, controlling the distance between adjacent CNF bundles by 500-1000 nm. The field emission characteristics of electrons from CNF bundles were evaluated and compared using current-voltage characteristic curves and a Fowler-Nordheim (F-N) plot converted using a work function value of 4.7 eV for CNFs. The field enhancement factor of FE characteristics obtained from the slopes in the F-N plot increased with the average distance defined as the space between adjacent CNF bundles. CNFs separately grown on a Ni-Cr catalyst are a candidate for effective two-dimensional field emitter devices.