Graphite encapsulated nanocrystals produced by a low carbon tungsten arc were analyzed to determine their chemistry, crystallography, and nanostructural morphology. Metallic nanocrystals of Fe, Co, and Ni are in the face-centered cubic (fcc) phase, and no trace of the bulk equilibrium phases of body-centered cubic (Fe) and hexagonal close-packed (Co) were found. Various analytical techniques have revealed that the encased nanocrystals are pure metal (some carbide was found in the case of Fe), ferromagnetic, and generally spherical. The nanocrystals are protected by turbostratic graphite, regardless of the size of the nanocrystals. The turbostratic graphite coating is usually made up of between 2 and 10 layers. No trace of any unwanted elements (e.g., oxygen) was found. The low carbon: metal ratio arc technique is a relatively clean process for the production of graphite encapsulated nanocrystals.
By systematically varying the carbon content, chamber pressure, arc current, and blowing gas velocity in a tungsten-arc encapsulation setup, the effects of each of these variables on the encapsulation of nickel in graphite layers were observed. The data from these optimally designed experiments revealed that the properties of the arc translate into changes in the encapsulated product. Specifically, a larger, hotter arc results in more encapsulation in the final sample. These findings, along with evidence of graphite layers which have formed on precrystallized particles, indicate that the graphite layers may form by two sequential formation steps. The first step is the simple phase segregation of carbon from a cooling liquid particle, resulting in surface graphite. The second step is the growth of carbon on a crystallized nickel particle, regardless of the temperature at which this occurs. The proposed formation mechanism has significant implications for both a scientific understanding of the encapsulation phenomena, and possible commercial applications.
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