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Synthesis of carbon nanotubes by fine Ni particles in Ni3Al foam

Abstract The reaction of Ni and Al particles may induce the formation of nickel aluminide intermetallics. However, the imcomplete reaction can produce very fine Ni particles, which are dispersed in a porous Ni3Al skeleton. The composite foam structure can then be used in the synthesis of carbon nanotubes (CNTs) at high temperatures. In this work, the process for this new structure, and then for synthesizing CNTs was investigated. Firstly, fine Ni particles in an Ni3Al porous structure formed by incomplete reaction between Ni and Al powder were made. Then, the effect of the addition of foaming agent, NaCl, on the porosity of the porous structure was studied. This showed that the porosity increases sharply with the addition of NaCl, and a porosity as high as 90% was obtained. Multi-walled CNTs were found in the products of catalytic decomposition of methanol by fine Ni particles in the composite foam structure. Finally, the potential applications of this composite foam structure in the low-cost manufacturing of CNTs, micro-channeled reactors and in-situ CNT reinforced composites are discussed.