The effect of powder sintering on the palladium-catalyzed formation of carbon nanofibers from ethylene–oxygen mixtures

Carbon nanofiber growth on palladium particles from ethylene–oxygen mixtures was investigated with respect to thermal history. Electron microscopy, combined with focused ion beam cross-sectioning show particles sinter quickly, but can be stabilized by the addition of a short carbon deposition step at a temperature below the general reaction temperature. This step generates a thin layer of carbon on the catalyst which reduces sintering once the temperature is raised to the optimal reaction temperature. For example, high temperature (e.g. 500 C) catalyst pre-treatment leads to catalyst particle sintering, and subsequent fiber growth produces large diameter fibers. In contrast, small diameter fibers form on catalyst particles pretreated at low temperature (ca. 350 C), even if the fibers are grown at a temperature at which deposition rates are faster (e.g. 550 C). These results led to the development of unique multiple temperature fiber growth protocols that produce smaller diameter fibers while improving the deposition rate. 2010 Elsevier Ltd. All rights reserved.