Taguchi optimized synthesis of graphene films by copper catalyzed ethanol decomposition

• The synthesis of graphene films by ethanol decomposition over Cu-foils is optimized.
• The most suited settings to obtain thin high-grade films are found by Taguchi method.
• Continuous films consisting of 2–4 nearly defect-free graphene layers are synthesized.

Taguchi method is for the first time applied to optimize the synthesis of graphene films by copper-catalyzed decomposition of ethanol. In order to find the most appropriate experimental conditions for the realization of thin high-grade films, six experiments suitably designed and performed. The influence of temperature (1000–1070 °C) and synthesis duration (1–30 min) and hydrogen flow (0–100 sccm) on the number of graphene layers and defect density in the graphitic lattice was ranked by monitoring the intensity of the 2D- and D-bands relative to the G-band in the Raman spectra. After critical examination and adjusting of the conditions predicted to give optimal results, a continuous film consisting of 2–4 nearly defect-free graphene layers was obtained.