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Single-crystal metals have distinctive properties owing to the absence of grain boundaries and strong anisotropy. Commercial single-crystal metals are usually synthesized by bulk crystal growth or by deposition of thin films onto substrates, and they are expensive and small. We prepared extremely large single-crystal metal foils by “contact-free annealing” from commercial polycrystalline foils. The colossal grain growth (up to 32 square centimeters) is achieved by minimizing contact stresses, resulting in a preferred in-plane and out-of-plane crystal orientation, and is driven by surface energy minimization during the rotation of the crystal lattice followed by “consumption” of neighboring grains. Industrial-scale production of single-crystal metal foils is possible as a result of this discovery.

A new approach to make graphitic thin films from graphene oxide (G-O) is presented. By incorporating small-diameter, reduced GO platelets with GO , graphitized films show improved density and crystalline order when compared with pure GO. Mechanical pressing of the graphitized films increased density but decreased crystallinity. A subsequent high-temperature heat treatment improved atomic order beyond that seen before mechanical pressing. In-plane thermal conductivity is on par with highly oriented pyrolytic graphite and exceeds commercially available graphite-based thermal interface materials.

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Chemiresistors were constructed using 3-D silica nanospring mats coated with a contiguous film of ZnO nanocrystals. Chemiresistors with an average ZnO nanocrystal radius <3 nm, or >20 nm, were found to exhibit a relative change in conductance of a factor of 50 upon exposure to a gas flow of 20% O2 and 80% N2 with ∼500 ppm of toluene and an operational temperature of 400 °C. Samples with an average ZnO nanocrystal radius of 15 nm were found to be the most responsive with a relative conductance change of a factor of 1000. The addition of metal nanoparticles (average radius equal to 2.4 nm) onto the surface of the ZnO nanocrystals (average radius equal to 15 nm) produced a relative change in conductance of a factor of 1500. For the optimum conditions (T = 400 °C, grain size ∼15 nm) well-defined spikes in conductance to explosive vapors (TNT, TATP) were obtained for 0.1 ms exposure time at ppb levels.

Chemiresistors (conductometric sensor) were fabricated on the basis of novel nanomaterials—silica nanosprings ALD coated with ZnO. The effects of high temperature and UV illumination on the electronic and gas sensing properties of chemiresistors are reported. For the thermally activated chemiresistors, a discrimination mechanism was developed and an integrated sensor-array for simultaneous real-time resistance scans was built. The integrated sensor response was tested using linear discriminant analysis (LDA). The distinguished electronic signatures of various chemical vapors were obtained at ppm level. It was found that the recovery rate at high temperature drastically increases upon UV illumination. The feasibility study of the activation method by UV illumination at room temperature was conducted.

A redox chemical sensor (chemiresistor) was constructed with a single ZnO coated silica nanospring. The chemiresistor response to toluene vapor as a function of the sensor temperature (T(NS)) and vapor temperature (T(V)) was measured and analyzed. The maximum sensitivity of the single ZnO coated nanospring device occurred at the sensor temperature (T(NS)) of 310 °C and at the vapor temperature (T(V)) of 250 °C. The characteristics of the electrical response of a single ZnO coated nanospring device were compared to those of a ZnO thin film. The single ZnO nanospring sensor was less responsive to small changes in toluene concentration relative to the ZnO thin film, but has a lower ultimate detection level. A computational model to simulate an electrical response of the single nanospring sensor and the thin film indicated that the differences between their response characteristics is due to the geometry of the nanospring and corresponding periodic boundary conditions imposed by the nanospring geometry, which is absent in a thin film.