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By leveraging decades of research on the catalytic synthesis of carbon nanofibers and combining it with unique processing methodology, low density monolithic carbon can be created. The process is simple, scalable and controllable. Analysis of deposition kinetics reveals that the final density of centimeter-scale carbon monoliths can be determined through basic process parameters, and the synthesis can be performed with a single step in as little as 1 h. In general, this material can be created over a large range of density (20–700 mg/cc), possesses high surface area (∼215 m 2 /g), is comprised of a mixture of straight and twisted carbon nanofibers (∼150–500 nm in diameter) with low crystallinity, which results in low electrical conductivity (1.32–2.83 S/m) and low thermal conductivity (∼0.03 W/mK), even at the highest densities. The materials are mechanically robust, with density-dependent elasticity values of 60–600 kPa. The methods and properties are discussed in context with other low-density carbon materials. The principal advantages of the process used in this work include the simplicity, direct control of density, and most notably, the ability to create this material with specific bulk geometry.

A unique type of nonwoven carbon material has been developed which is flexible, resilient, and produced at modest temperature and near ambient pressure using catalytic deposition. This material is comprised entirely of nanoscale carbon fibers, which are extensively interlaced to create a coherent, bulk material. The structure and basic mechanical and electrical properties of this material were investigated through cyclic compression and in situ resistance measurement. The material was highly elastic and capable of being repeatedly compressed without disintegration. The mechanical response varied with density, and the density was controlled by the amount of catalyst used. The material exhibited a high electrical resistivity, which varied nonlinearly with compression.

The rate of catalytic carbon nanofiber formation from a mixture of ethylene and hydrogen at 550 °C was found to be dramatically faster over physical mixtures of palladium and cobalt micron scale particles than over either metal independently. The rate correlated with the metal fraction nearly identically for either Pd or Co rich mixtures. The highest rate increase over either pure metal was observed for a 1:1 mass ratio (∼150 times faster), although significant increases were found even at metal ratios of 11:1 (∼45 times faster). There was no direct evidence of extensive alloy formation from the mixed powders which suggests that a synergistic mechanism driven by proximity only may be responsible for the observed rate increases. It is thought a species (e.g. hydrogen atoms) formed at one metal (e.g. palladium) diffuses to the other where it accelerates carbon deposition by affecting the other catalyst material directly, or by generating favorable radical species. Kinetic synergism was also observed for Pd–Co alloys, although it was clearly less dramatic than that found for mixtures. Still, the fundamental similarity in behavior suggests that on the alloy surface two site types exist: one primarily Pd and one primarily Co.

Carbon nanofiber growth on palladium particles from ethylene–oxygen mixtures was investigated with respect to thermal history. Electron microscopy, combined with focused ion beam cross-sectioning show particles sinter quickly, but can be stabilized by the addition of a short carbon deposition step at a temperature below the general reaction temperature. This step generates a thin layer of carbon on the catalyst which reduces sintering once the temperature is raised to the optimal reaction temperature. For example, high temperature (e.g. 500 °C) catalyst pre-treatment leads to catalyst particle sintering, and subsequent fiber growth produces large diameter fibers. In contrast, small diameter fibers form on catalyst particles pretreated at low temperature (ca. 350 °C), even if the fibers are grown at a temperature at which deposition rates are faster (e.g. 550 °C). These results led to the development of unique multiple temperature fiber growth protocols that produce smaller diameter fibers while improving the deposition rate.

The characteristics of carbonaceous materials deposited in fuel rich ethylene–oxygen mixtures on three types of palladium: foil, sputtered film, and nanopowder, are reported. It was found that the form of palladium has a dramatic influence on the morphology of the deposited carbon. In particular, on sputtered film and powder, tight ‘weaves’ of sub-micron filaments formed quickly. In contrast, on foils under identical conditions, the dominant morphology is carbon thin films with basal planes oriented parallel to the substrate surface. Temperature, gas flow rate, reactant flow ratio (C2H4:O2), and residence time (position) were found to influence both growth rate and type for all three forms of Pd. X-ray diffraction, high resolution transmission electron microscopy, temperature-programmed oxidation, and Raman spectroscopy were used to assess the crystallinity of the as-deposited carbon, and it was determined that transmission electron microscopy and X-ray diffraction were the most reliable methods for determining crystallinity. The dependence of growth on reactor position, and the fact that no growth was observed in the absence of oxygen support the postulate that the carbon deposition proceeds by combustion generated radical species.