Flame synthesis of carbon nanotubes with high density on stainless steel mesh

Multi-walled carbon nanotubes grew directly on wires of stainless steel mesh in controllable methane diffusion flames. The formation and morphology of carbon nanotubes were dependent on gas composition of the flames. On pre-etched mesh wires with HCl, high density of carbon nanotubes were synthesized with uniform outer diameters of 60 nm and large inner diameters of 50 nm. With the high yield of carbon nanotubes, less carbon impurities were formed in the process. A mechanistic model was proposed in detail to suggest the formation of catalyst directly on bulk surface and explain the whole process of carbon nanotubes growth in this study.