Abstract
Vertically aligned carbon nanofibers (VACNFs) were grown by plasma-enhanced
chemical vapor deposition (PECVD) using Ni nanoparticle (NP) catalysts that were deposited by
airbrushing onto Si, Al, Cu, and Ti substrates. Airbrushing is a simple method for depositing
catalyst NPs over large areas that is compatible with roll-to-roll processing. The distribution and
morphology of VACNFs are affected by the airbrushing parameters and the composition of the
metal foil. Highly concentrated Ni NPs in heptane give more uniform distributions than pentane
and hexanes, resulting in more uniform coverage of VACNFs. For VACNF growth on metal
foils, Si micropowder was added as a precursor for Si-enriched coatings formed in situ on the
VACNFs that impart mechanical rigidity. Interactions between the catalyst NPs and the metal
substrates impart control over the VACNF morphology. Growth of carbon nanostructures on Cu
is particularly noteworthy because the miscibility of Ni with Cu poses challenges for VACNF
growth, and carbon nanostructures anchored to Cu substrates are desired as anode materials for
Li-ion batteries and for thermal interface materials.
