Compositional-Spread Discovery of Catalysts for the Growth of Long-Length Dense Forests of Vertically Aligned Carbon Nanotubes

The growth of dense forests of vertically aligned arrays of multi-walled carbon nanotubes (VAA-MWNTs) by chemical vapor deposition [CVD] from a single metallic catalyst layer typically self-terminates after only a few hundred microns of tube length. In order to obtain maximal growth to long lengths, a systematic simultaneous study of catalyst composition and thickness is needed performed here by a compositional-spread approach. Using Pulsed-Laser Deposition (PLD), metallic layers with a wedge-shaped thickness profile are deposited onto Al-coated silicon substrates. High temperature annealing of the metal catalyst films in flowing Ar/H2 gas followed by the one-hour growth of VA-MWNTs by CVD using acetylene gas yields VAA-MWNTs. Tube height (and thus the catalytic activity) is determined as function of position and can be analyzed as a function of catalyst thickness and composition. A dependence of tube height as function of catalyst composition (Mo/Fe ratio) demonstrates that a specific catalyst composition exhibits a local maximum in catalytic activity, permitting the extension of nanotube array growth up to 4 millimeters in height. Other combinations of catalysts and the growth of single-walled tubes will be discussed. This research was sponsored by the U.S. Department of Energy under contract DE-AC05-00OR22725 with the Oak Ridge National Laboratory, managed by UT-Battelle, LLC, and the Laboratory-Directed Research and Development Program at ORNL.