Scalable CVD synthesis of three-dimensional graphene from cast catalyst

DeArmond, Derek; Zhang, Lu; Malik, Rachit; Reddy, K. Vamsi Krishna; Alvarez, Noe T.; Haase, Mark; Hsieh, Yu-Yun; Kanakaraj, Sathya Narayan; Oslin, Nick; Brunemann, James; Daum, Jeremy; Shanov, Vesselin

doi:10.1016/j.mseb.2020.114510

Cited by 20 publications

(16 citation statements)

References 42 publications

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“…In Figure a, the TGA curve is represented in black color, and its first derivative (DTG) is plotted as a blue curve. A large peak was observed between 550 and 780 °C, reaching a maximum of around 700 °C, illustrating the start and end of the oxidation and burning of crystalline carbon in the sample. , No other peaks were observed except for a steady decrease in weight percentage with an increase in temperature. The TGA curve also interprets the stability of 3D 2 G at higher temperature considering only a loss of around 5% weight by 500 °C.…”

Section: Resultsmentioning

confidence: 94%

“…Based on the thermal degradation data acquired from TGA, a similar temperature profile used in our previous works , was employed for the CVD synthesis of 3D 2 G. An ET-1000 First Nano reactor was used for the CVD synthesis and the procedure was described elsewhere. , In brief, the CVD synthesis was conducted in four steps. After loading the sample inside the reactor, it was heated from room temperature to 1000 °C in 40 min in the presence of argon (1000 sccm) and hydrogen (325 sccm) gas mixture.…”

Section: Cvd Synthesis Of 3d2gmentioning

confidence: 99%

“…Top-down approaches involve the separation of graphene from graphite using different forms of energy. A bottom-up approach like chemical vapor deposition (CVD) is very popular for the synthesis of graphene, employing a metal catalyst substrate exposed to a gaseous carbon precursor at elevated temperatures in inert or reducing atmospheres. , Top-down approaches result in graphene with a lot of structural defects along with high cost and inconsistent results . On the other hand, CVD produces defect-free high-quality graphene with almost zero interfacial resistance between graphene flakes within the 2D graphene plane as all the carbon atoms are bonded via strong sigma bonds.…”

Section: Introductionmentioning

confidence: 99%

“…When cooled down, the dissolved carbon precipitates out, resulting in graphene formation on the surface of the substrate . Furthermore, the properties of graphene can be manipulated by making modifications to the metal catalyst or to the CVD reactor environment. ,, Nonetheless, the practical applications of graphene are limited by its 2D nature. Thus, there is an urge to fabricate three-dimensional (3D) graphene structure which can be easily handled and can preserve the exceptional properties of its 2D form.…”

Section: Introductionmentioning

confidence: 99%

“…The requirement for compression force and the high cost of the used compression tools/dies increase the process cost and make this approach susceptible for the synthesis of 3D graphene with shape and structure control. Furthermore, our recent work on the CVD synthesis of 3D graphene using a knife-casted nickel–polymer catalyst produced a high-quality and scalable 3D graphene sheet, thus avoiding the compression of catalyst particles . The nickel–polymer catalyst precursor is cost-effective and scalable and can be cut into various shapes and sizes to fit the CVD reactor.…”

Section: Introductionmentioning

confidence: 99%

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CVD Synthesis of 3D-Shaped 3D Graphene Using a 3D-Printed Nickel–PLGA Catalyst Precursor

Kondapalli

Khosravifar

et al. 2021

ACS Omega

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Earlier, various attempts to develop graphene structures using chemical and nonchemical routes were reported. Being efficient, scalable, and repeatable, 3D printing of graphene-based polymer inks and aerogels seems attractive; however, the produced structures highly rely on a binder or an ice support to stay intact. The presence of a binder or graphene oxide hinders the translation of the excellent graphene properties to the 3D structure. In this communication, we report our efforts to synthesize a 3D-shaped 3D graphene (3D 2 G) with good quality, desirable shape, and structure control by combining 3D printing with the atmospheric pressure chemical vapor deposition (CVD) process. Direct ink writing has been used in this work as a 3D-printing technique to print nickel powder−PLGA slurry into various shapes. The latter has been employed as a catalyst for graphene growth via CVD. Porous 3D 2 G with high purity was obtained after etching out the nickel substrate. The conducted micro CT and 2D Raman study of pristine 3D 2 G revealed important features of this new material. The interconnected porous nature of the obtained 3D 2 G combined with its good electrical conductivity (about 17 S/cm) and promising electrochemical properties invites applications for energy storage electrodes, where fast electron transfer and intimate contact with the active material and with the electrolyte are critically important. By changing the printing design, one can manipulate the electrical, electrochemical, and mechanical properties, including the structural porosity, without any requirement for additional doping or chemical postprocessing. The obtained binderfree 3D 2 G showed a very good thermal stability, tested by thermo-gravimetric analysis in air up to 500 °C. This work brings together two advanced manufacturing approaches, CVD and 3D printing, thus enabling the synthesis of high-quality, binder-free 3D 2 G structures with a tailored design that appeared to be suitable for multiple applications.

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Section: Resultsmentioning

confidence: 94%

Section: Cvd Synthesis Of 3d2gmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

CVD Synthesis of 3D-Shaped 3D Graphene Using a 3D-Printed Nickel–PLGA Catalyst Precursor

Kondapalli

Khosravifar

et al. 2021

ACS Omega

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Silicon Radical‐Induced CH₄ Dissociation for Uniform Graphene Coating on Silica Surface

Pirabul,

Zhao,

Pan

et al. 2023

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Due to the manufacturability of highly well‐defined structures and wide‐range versatility in its microstructure, SiO2 is an attractive template for synthesizing graphene frameworks with the desired pore structure. However, its intrinsic inertness constrains the graphene formation via methane chemical vapor deposition. This work overcomes this challenge by successfully achieving uniform graphene coating on a trimethylsilyl‐modified SiO2 (denote TMS‐MPS). Remarkably, the onset temperature for graphene growth dropped to 720 °C for the TMS‐MPS, as compared to the 885 °C of the pristine SiO2. This is found to be mainly from the Si radicals formed from the decomposition of the surface TMS groups. Both experimental and computational results suggest a strong catalytic effect of the Si radicals on the CH4 dissociation. The surface engineering of SiO2 templates facilitates the synthesis of high‐quality graphene sheets. As a result, the graphene‐coated SiO2 composite exhibits a high electrical conductivity of 0.25 S cm−1. Moreover, the removal of the TMP‐MPS template has released a graphene framework that replicates the parental TMS‐MPS template on both micro‐ and nano‐ scales. This study provides tremendous insights into graphene growth chemistries as well as establishes a promising methodology for synthesizing graphene‐based materials with pre‐designed microstructures and porosity.

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Bio-waste-derived few-layered graphene/SrTiO3/PAN as efficient photocatalytic system for water splitting

Daulbayev

Sultanov

Korobeinyk

et al. 2021

Applied Surface Science

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Scalable CVD synthesis of three-dimensional graphene from cast catalyst

Cited by 20 publications

References 42 publications

CVD Synthesis of 3D-Shaped 3D Graphene Using a 3D-Printed Nickel–PLGA Catalyst Precursor

CVD Synthesis of 3D-Shaped 3D Graphene Using a 3D-Printed Nickel–PLGA Catalyst Precursor

Silicon Radical‐Induced CH₄ Dissociation for Uniform Graphene Coating on Silica Surface

Bio-waste-derived few-layered graphene/SrTiO3/PAN as efficient photocatalytic system for water splitting

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Scalable CVD synthesis of three-dimensional graphene from cast catalyst

Cited by 20 publications

References 42 publications

CVD Synthesis of 3D-Shaped 3D Graphene Using a 3D-Printed Nickel–PLGA Catalyst Precursor

CVD Synthesis of 3D-Shaped 3D Graphene Using a 3D-Printed Nickel–PLGA Catalyst Precursor

Silicon Radical‐Induced CH4 Dissociation for Uniform Graphene Coating on Silica Surface

Bio-waste-derived few-layered graphene/SrTiO3/PAN as efficient photocatalytic system for water splitting

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Product

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About

Silicon Radical‐Induced CH₄ Dissociation for Uniform Graphene Coating on Silica Surface