Block-copolymer assisted synthesis of arrays of metal nanoparticles and their catalytic activities for the growth of SWNTs

Block copolymer micellar templates were used for the controlled synthesis of large arrays of mono-metallic (Fe, Co, Ni, Mo) and bi-metallic (Fe–Mo) nanoparticles with average diameters ranging from 1 to 4 nm and the distance between the nanoparticles ranging from 40 to 45 nm. XPS data reveal the presence of mono-metallic nanoparticles in their oxidized states. These uniform arrays of nanoparticles serve as an excellent tool to investigate the catalytic effect of different metal/metal oxide nanoparticles for the growth of carbon nanotubes, and in this work, they were used to investigate the growth of single-walled carbon nanotubes with the chemical vapour deposition (CVD) process, using both ethanol and hydrocarbon (methane + ethylene) gases as carbon sources. The periodicity and the arrangement of nanoparticles were unaffected even at high growth temperatures, indicating that nanoparticle agglomeration on the Si substrate does not take place during growth. AFM and SEM results reveal uniform growth of nanotubes with diameters smaller than the initial size of the catalyst nanoparticles. The Fe, Co and Ni nanoparticles all serve as effective catalysts for nanotube growth with both types of carbon feed stock, and Co and Ni give rise to a relatively higher yield than Fe. The catalytic activity of Fe and bi-metallic Fe–Mo nanoparticles of similar size and identical densities using ethanol CVD are also compared. (Some figures in this article are in colour only in the electronic version)