| With multiple outstanding properties, such as high Young's modulus, high strength, good thermal conductivity and electrical conductivity, carbon nanotube (CNT) has been considered as a new generation of material that has many potential applications in many fields. One obstacle that stands in the way of applying CNTs in the real world is the limited growth length. Catalyst instability is one of the many factors that cause the stops of CNT growth. In this research, intermetalic Fe-Zr catalyst was used to grow millimeter long CNT arrays. The Fe-Zr particles enabled the growth of 1.7 millimeter long carbon nanotube arrays in 45 minutes. A comparison with pure Fe catalyst indicated that adding Zr to iron can stabilize the Fe catalyst at the CNT growth temperature and moderate its reactivity.;In future, when CNTs are largely used in industrial, mass production of CNTs at a low cost is vital for market competition. In many current CNT growth methods, a process of depositing a thin catalyst film on top of Al 2O3 film on a piece of silicon wafer is required. Thus the size of CNT samples is limited by the size of the largest silicon wafer currently available, which is 8 inch in diameter. In this study, FeCl2 powders were used as the catalyst to grow CNT arrays not only on traditional silicon substrates but also on quartz substrates and carbon sheets. This unique method does not require the thin film deposition step, which shortens the time used for each batch of CNT growth. The simplicity of this method allows an easy scale-up for mass production of CNTs with a low cost. In order to improve this method, HCl was used to assist the CNT growth. HCl was added via flowing a small amount of C2H2 thorough a bubbuler where HCl solution was contained. With the assistance of HCl, CNT growth could be extended to 1 hour. 3 mm tall non-spinnable arrays and 2 mm tall spinnable arrays were produced using this method.;With the increasing use of composite materials, real time health monitoring of composite structures becomes vital for maintenance purpose as well as prevention of catastrophic failure. In this research, a novel prototype of CNT fiber sensor with excellent repeatability and stability was applied for in-situ structural health monitoring. The CNT fiber was spun directly from CNT arrays, and its electrical resistance increases linearly with tensile strain, which makes it an ideal strain sensor. Importantly, it shows consistent piezoresistive behavior under repetitive straining and unloading, and good stability at temperatures ranging from 77K to 373K. CNT fiber sensors can be easily embedded into composite structures with minimal invasiveness and weight penalty due to the lightweight and good mechanical properties of fibers. With multiple fibers aligned in the composite, crack initiation and propagation could be monitored in situ. |
