By using a thin layer of catalyst, Professor of Physics Zhifeng Ren and researcher Dr. Hengzhi Wang discovered two previously overlooked stages of carbon nanotube growth, they report. The method yields a first stage where budding tubes appear randomly entangled, then a second stage of partially aligned tubes, then a third and final stage of tubes in full alignment, which is the standard used by researchers who produce carbon nanotubes for use in a range of materials and biomedical research.
"These growth phases are controlled by the thickness of the catalyst in use," said Wang. "Each stage, it turns out, has its own merit. Each stage has its own purpose."
In plasma enhanced chemical vapor deposition, carbon nanotubes are grown through the repeated accumulation of carbon atoms from the decomposition of gasses upon a catalyst particle, which creates multilayered carbon material on a substrate. Researchers have sought to create neatly aligned rows of millions of carbon nanotubes upon the substrates.
Nanotechnology Journal - The evolution of carbon nanotubes during their growth by plasma enhanced chemical vapor deposition
During the growth of carbon nanotubes (CNTs) by plasma enhanced chemical vapor deposition (PECVD), plasma etching is the crucial factor that determines the growth mode and alignment of the CNTs. Focusing on a thin catalyst coating (Ni = 5 nm), this study finds that the CNT growth by PECVD goes through three stages from randomly entangled (I-CNTs) to partially aligned (II-CNTs) to fully aligned (III-CNTs). The I-CNTs and II-CNTs are mostly etched away by the plasma as time goes by ending up with III-CNTs as the only product when growth time is long enough. However, with a thickness of the catalyst coating of 10 nm or more, neither I-CNTs nor II-CNTs are produced, but III-CNTs are the only type of CNTs grown during the whole growth process. During the growth of III-CNTs, the catalyst particles (Ni) stay on the tips of each of the aligned CNTs and act as a 'safety helmet' to protect the CNTs from plasma ion bombardment. On the other hand, it is also the plasma that limits the growth of III-CNTs, since the plasma eventually etches all the catalytic particles out and stops the growth.
Ren and Wang say that in the process of achieving the third stage of nanotube growth, the two earlier phases of growth have gone overlooked as each stage is etched away by the next application of plasma. Further masking these early-stage carbon nanotubes is the fact that they are not present when a thick catalyst is used, according to their findings.
The first stage tubes, produced in zero to four minutes, are described as a tangle of random large and small diameter carbon nanotubes. The second stage tubes, created in four to ten minutes, are generally smaller in diameter, but taller and only partially aligned.
Wang says that while these nanotubes are not in neat, orderly rows, they do have the advantage of offer a larger volumetric density and create a larger surface area, which could be an important development in the use of carbon nanotubes in heat transfer in thermal management. A potential application could involve in applying a thin coating of carbon nanotubes to an integrated circuit in order to draw away heat and efficiently cool the device.
After ten minutes of plasma etching, the early stage nanotubes have been washed away and the third stage tubes begin to emerge in tall, ordered rows upon the substrate. At this stage, the tubes themselves are shielded by makeshift "helmets" of catalyst particles, which effectively protect them during the last part of the growth process. Eventually, these last bits of catalyst are etched away as well
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