Controlled assembly of graphene shells encapsulated gold nanoparticles and their integration with carbon nanotubes

Controlled growth and uniform patterning of graphene/carbon shells encapsulated gold nanoparticles (GNPs) on silicon wafer or on high curvature carbon nanotubes (CNTs) is reported here. This was achieved by utilizing patterned gold nanoparticles with controlled sizes (∼30–600 nm) via gold film dewetting process. Surface-oxidized and patterned nanoparticles were used as sacrificial catalysts for the chemical vapor deposition (CVD) growth of graphene/carbon shells. The shell morphological evolution and thickness as well as surface migration of nanoparticles during the CVD process were studied as a function of the gold nanoparticles size. Reduced surface migration and coalescence was observed for gold nanoparticles after the CVD growth and this was attributed to the initial formation of graphene/carbon shells as well as stable dispersion of the dewetted gold nanoparticles. It is proposed that graphene/carbon shell growth was controlled by Ostwald’s ripening, surface gold oxide, and reducing CVD growth environment. Furthermore, complex heterostructures based on CNTs coated with GNPs were fabricated by dewetting Au films on CNTs and followed by surface oxidation and CVD growth steps. CNTs successfully survived multiple processing steps and selective growth of graphene shells around Au nanoparticles was achieved and studied using microscopic and spectroscopic methods.