Catalytic chemical vapor deposition synthesis of single- and double-walled carbon nanotubes from α-(Al1−xFex)2O3 powders and self-supported foams

An investigation of the potential interest of α-alumina–hematite foams, as opposed to powders, as starting materials for the synthesis of carbon nanotubes (CNTs) by catalytic chemical vapor deposition method was performed. The oxide powders and foams as well as the corresponding CNT–Fe–Al2O3 composite powders and foams are studied by X-ray diffraction, specific surface area measurements, electron microscopy, Raman spectroscopy and Mössbauer spectroscopy. The latter technique revealed that four components (corresponding to α-Fe, Fe3C, γ-Fe-C and Fe3+) were present in the Mössbauer spectra of the composite powders, and that an additional sextet, possibly due to an Fe1−yCy alloy, is also present in the Mössbauer spectra of the composite foams. Contrary to some expectations, using foams do not lead to an easier reduction and thus to the formation of more α-Fe, Fe3C and/or γ-Fe–C potentially active particles for the formation of CNTs, and hence to no gain in the quantity of CNTs. However, using foams as starting materials strongly favors the selectivity of the method towards SWCNTs (60% SWCNTs and 40% DWCNTs) compared to what is obtained using powders (5% SWCNTs, 65% DWCNTs and 30% MWCNTs).