In this work, we present large scale, ultralight aligned carbon nanotube (CNT) structures which have densities an order of magnitude lower than CNT arrays, have tunable properties and exhibit resiliency after compression. By stacking aligned sheets of carbon nanotubes and then infiltrating with a pyrolytic carbon (PyC), resilient foam-like materials were produced that exhibited complete recovery from 90% compressive strain. With density as low as 3.8 mg cm(-3), the foam structure is over 500 times less dense than bulk graphite. Microscopy revealed that PyC coated the junctions among CNTs, and also increased CNT surface roughness. These changes in the morphology explain the transition from inelastic behavior to foam-like recovery of the layered CNT sheet structure. Mechanical and thermal properties of the foams were tuned for different applications through variation of PyC deposition duration while dynamic mechanical analysis showed no change in mechanical properties over a large temperature range. Observation of a large and linear electrical resistance change during compression of the aligned CNT/carbon (ACNT/C) foams makes strain/pressure sensors a relevant application. The foams have high oil absorption capacities, up to 275 times their own weight, which suggests they may be useful in water treatment and oil spill cleanup. Finally, the ACNT/C foam's high porosity, surface area and stability allow for demonstration of the foams as catalyst support structures.
Carbon coated aligned multi-walled carbon nanotube (AMWCNT/C) sheets were used for studying the controlled radial growth of MWCNTs. Pyrolytic carbon (PyC) was deposited on the surface of nanotubes using multiple cycles of chemical vapor infiltration. Morphological and structural characterization showed that when graphitization was done in one step, after the deposition of multiple cycles of PyC, the presence of a large amount of disordered carbon on the surface of nanotubes led to a poorly graphitized coating structure that did not resembled nanotube walls anymore. Graphitization of the AMWCNT/C sheets after each deposition cycle prevented the development of disordered carbon during the subsequent PyC deposition cycles. Using the cyclic-graphitization method, thick PyC coating layers were successfully graphitized into a crystalline structure that could not be differentiated from the original nanotube walls. TEM observation and X-ray data confirmed radial growth of nanotubes, while spectra collected from Raman spectroscopy revealed that radially grown CNTs had the
Record-breaking ultralow density aluminum oxide structures are prepared using a novel templating technique. The alumina structures are unique in that they are comprised by highly aligned and interconnected nanotubes yielding anisotropic behavior. Large-scale network structures with complex form-factors can easily be made using this technique. The application of the low density networks as humidity sensing materials as well as thermal insulation is demonstrated.
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