Advances in the synthesis and scalable manufacturing of single-walled carbon nanotubes (SWCNTs) remain critical to realizing many important commercial applications. Here we review recent breakthroughs in the synthesis of SWCNTs and highlight key ongoing research areas and challenges. A few key applications that capitalize on the properties of SWCNTs are also reviewed with respect to the recent synthesis breakthroughs and ways in which synthesis science can enable advances in these applications. While the primary focus of this review is on the science framework of SWCNT growth, we draw connections to mechanisms underlying the synthesis of other 1D and 2D materials such as boron nitride nanotubes and graphene.

We explain the evolution and termination of vertically aligned carbon nanotube (CNT) “forests” by a collective mechanism, which is verified by temporal measurements of forest mass and height, as well as quantitative spatial mapping of CNT alignment by synchrotron X-ray scattering. We propose that forest growth consists of four stages: (I) self-organization; (II) steady growth with a constant CNT number density; (III) decay with a decreasing number density; and (IV) abrupt self-termination, which is coincident with a loss of alignment at the base of the forest. The abrupt loss of CNT alignment has been observed experimentally in many systems, yet termination of forest growth has previously been explained using models for individual CNTs, which do not consider the evolution of the CNT population. We propose that abrupt termination of CNT forest growth is caused by loss of the self-supporting structure, which is essential for formation of a CNT forest in the first place, and that this event is triggered by accumulating growth termination of individual CNTs. A finite element model accurately predicts the critical CNT number density at which forest growth terminates and demonstrates the essential role of mechanical contact in maintaining growth of self-assembled films of filamentary nanostructures.

Understanding the population growth behavior of filamentary nanostructures, such as carbon nanotubes (CNTs), is hampered by the lack of characterization techniques capable of probing statistical variations with high spatial resolution. We present a comprehensive methodology for studying the population growth dynamics of vertically aligned CNT forests, utilizing high-resolution spatial mapping of synchrotron X-ray scattering and attenuation, along with real-time height kinetics. We map the CNT alignment and dimensions within CNT forests, revealing broadening and focusing of size distributions during different stages of the process. Then, we calculate the number density and mass density of the CNT population versus time, which are true measures of the reaction kinetics. We find that the mass-based kinetics of a CNT population is accurately represented by the S-shaped Gompertz model of population growth, although the forest height and CNT length kinetics are essentially linear. Competition between catalyst activation and deactivation govern the rapid initial acceleration and slow decay of the CNT number density. The maximum CNT density (i.e., the overall catalyst activity) is limited by gas-phase reactions and catalyst-surface interactions, which collectively exhibit autocatalytic behavior. Thus, we propose a comprehensive picture of CNT population growth which combines both chemical and mechanical cooperation. Our findings are relevant to both bulk and substrate-based CNT synthesis methods and provide general insights into the self-assembly and collective growth of filamentary nanostructures.

We study synthesis of vertically aligned carbon nanotube (CNT) "forests" by a decoupled method that facilitates control of the mean diameter and structural quality of the CNTs and enables tuning of the kinetics for efficient growth to forest heights of several millimeters. The growth substrate temperature (T(s)) primarily determines the CNT diameter, whereas independent and rapid thermal treatment (T(p)) of the C(2)H(4)/H(2) reactant mixture significantly changes the growth rate and terminal forest height but does not change the CNT diameter. Synchrotron X-ray scattering is utilized for precise, nondestructive measurement of CNT diameter in large numbers of samples. CNT structural quality monotonically increases with T(s) yet decreases with T(p), and forests grown by this decoupled method have significantly higher quality than those grown using a conventional single-zone tube furnace. Chemical analysis reveals that the thermal treatment generates a broad population of hydrocarbon species, and a nonmonotonic relationship between catalyst lifetime and T(p) suggests that certain carbon species either enhance or inhibit CNT growth. However, the forest height kinetics, as measured in real-time during growth, are self-similar, thereby indicating that a common mechanism of growth termination may be present over a wide range of process conditions.

Small-diameter carbon nanotubes (CNTs) are shown to enable exceptionally fast transport of water vapor under a concentration gradient driving force. Thanks to this property, membranes having sub-5 nm CNTs as conductive pores feature outstanding breathability while maintaining a high degree of protection from biothreats by size exclusion.

Real-time height measurements demonstrate that growth of millimeter-high carbon nanotube ͑CNT͒ forests terminates abruptly after first exhibiting a steady decay in growth rate. Termination is accompanied by a distinct loss of alignment among the CNTs, which is quantified by small-angle x-ray scattering. Previously suggested diffusion-limited and decay-limited models of kinetics accurately fit the growth period, yet fail to capture the termination behavior and incorrectly predict that growth will continue for much longer durations than observed. It appears that structural disorder is a distinct chemical and/or mechanical signature of self-terminated CNT forest growth.

Thermal treatments of feedstock gases (e.g., C(2)H(4)/H(2)) used during carbon nanotube (CNT) synthesis result in the formation of a complex mixture of volatile organic compounds and polycyclic aromatic hydrocarbons. Some of these are likely important CNT precursors, while others are superfluous and possibly degrade product quality, form amorphous carbon, and/or contribute to growth termination. To simulate the effect of thermal treatment without this chemical complexity, we delivered trace amounts of individual hydrocarbons, along with ethylene and hydrogen, to a cold-wall atmospheric pressure reactor containing a locally heated metal catalyst (Fe on Al(2)O(3)). Using these compound-specific experiments, we demonstrate that many alkynes (e.g., acetylene, methyl acetylene, and vinyl acetylene) accelerate multiwalled CNT formation with this catalyst system. Furthermore, ethylene is required for enhanced CNT growth, suggesting that the alkyne and ethylene may react in concert at the metal catalyst. This presents a distinct CNT formation mechanism where the chemical precursors may be intact during C-C bond formation, such as in polymerization reactions, challenging the widely accepted hypothesis that precursors completely dissociate into C (or C(2)) units before "precipitating" from the metal. Armed with these mechanistic insights, we were able to form high-purity CNTs rapidly with a 15-fold improvement in yield, a 50% reduction in energetic costs, and order of magnitude reduction in unwanted byproduct formation (e.g., toxic and smog-forming chemicals and greenhouse gases).

Understanding the collective growth of carbon nanotube (CNT) populations is key to tailoring their properties for many applications. During the initial stages of CNT growth by chemical vapor deposition, catalyst nanoparticle formation by thin-film dewetting and the subsequent CNT nucleation processes dictate the CNT diameter distribution, areal density, and alignment. Herein, we use in situ environmental transmission electron microscopy (E-TEM) to observe the catalyst annealing, growth, and deactivation stages for a population of CNTs grown from a thin-film catalyst. Complementary in situ electron diffraction and TEM imaging show that, during the annealing step in hydrogen, reduction of the iron oxide catalyst is concomitant with changes in the thin-film morphology; complete dewetting and the formation of a population of nanoparticles is only achieved upon the introduction of the carbon source, acetylene. The dewetting kinetics, i.e., the appearance of distinct nanoparticles, exhibits a sigmoidal (autocatalytic) curve with 95% of all nanoparticles appearing within 6 s. After nanoparticles form, they either nucleate CNTs or remain inactive, with incubation times measured to be as small as 3.5 s. Via E-TEM we also directly observe the crowding and self-alignment of CNTs after dewetting and nucleation. In addition, in situ electron energy loss spectroscopy reveals that the collective rate of carbon accumulation decays exponentially. We conclude that the kinetics of catalyst formation and CNT nucleation must both be addressed in order to achieve uniform and high CNT density, and their transient behavior may be a primary cause of the well-known nonuniform density of CNT forests.