Marcus A. Worsley

Synthesis of Graphene Aerogel with High Electrical Conductivity

We report the synthesis of ultra-low-density three-dimensional macroassemblies of graphene sheets that exhibit high electrical conductivities and large internal surface areas. These materials are prepared as monolithic solids from suspensions of single-layer graphene oxide in which organic sol-gel chemistry is used to cross-link the individual sheets. The resulting gels are supercritically dried and then thermally reduced to yield graphene aerogels with densities approaching 10 mg/cm(3). In contrast to methods that utilize physical cross-links between GO, this approach provides covalent carbon bonding between the graphene sheets. These graphene aerogels exhibit an improvement in bulk electrical conductivity of more than 2 orders of magnitude (∼1 × 10(2) S/m) compared to graphene assemblies with physical cross-links alone (∼5 × 10(-1) S/m). The graphene aerogels also possess large surface areas (584 m(2)/g) and pore volumes (2.96 cm(3)/g), making these materials viable candidates for use in energy storage, catalysis, and sensing applications.

Advanced carbon aerogels for energy applications

Carbon aerogels are a unique class of high-surface-area materials derived by sol–gel chemistry. Their high mass-specific surface area and electrical conductivity, environmental compatibility and chemical inertness make them very promising materials for many energy related applications, specifically in view of recent developments in controlling their morphology. In this perspective we will review the synthesis of monolithic resorcinol–formaldehyde based carbon aerogels with hierarchical porosities for energy applications, including carbon nanotube and graphene composite carbon aerogels, as well as their functionalization by surface engineering. Applications that we will discuss include hydrogen and electrical energy storage, desalination and catalysis.

Highly compressible 3D periodic graphene aerogel microlattices

Graphene is a two-dimensional material that offers a unique combination of low density, exceptional mechanical properties, large surface area and excellent electrical conductivity. Recent progress has produced bulk 3D assemblies of graphene, such as graphene aerogels, but they possess purely stochastic porous networks, which limit their performance compared with the potential of an engineered architecture. Here we report the fabrication of periodic graphene aerogel microlattices, possessing an engineered architecture via a 3D printing technique known as direct ink writing. The 3D printed graphene aerogels are lightweight, highly conductive and exhibit supercompressibility (up to 90% compressive strain). Moreover, the Youngs moduli of the 3D printed graphene aerogels show an order of magnitude improvement over bulk graphene materials with comparable geometric density and possess large surface areas. Adapting the 3D printing technique to graphene aerogels realizes the possibility of fabricating a myriad of complex aerogel architectures for a broad range of applications.

Nanoscale Zirconia as a Nonmetallic Catalyst for Graphitization of Carbon and Growth of Single- and Multiwall Carbon Nanotubes

We report that nanoparticulate zirconia (ZrO(2)) catalyzes both growth of single-wall and multiwall carbon nanotubes (CNTs) by thermal chemical vapor deposition (CVD) and graphitization of solid amorphous carbon. We observe that silica-, silicon nitride-, and alumina-supported zirconia on silicon nucleates single- and multiwall carbon nanotubes upon exposure to hydrocarbons at moderate temperatures (750 degrees C). High-pressure, time-resolved X-ray photoelectron spectroscopy (XPS) of these substrates during carbon nanotube nucleation and growth shows that the zirconia catalyst neither reduces to a metal nor forms a carbide. Point-localized energy-dispersive X-ray spectroscopy (EDAX) using scanning transmission electron microscopy (STEM) confirms catalyst nanoparticles attached to CNTs are zirconia. We also observe that carbon aerogels prepared through pyrolysis of a Zr(IV)-containing resorcinol-formaldehyde polymer aerogel precursor at 800 degrees C contain fullerenic cage structures absent in undoped carbon aerogels. Zirconia nanoparticles embedded in these carbon aerogels are further observed to act as nucleation sites for multiwall carbon nanotube growth upon exposure to hydrocarbons at CVD growth temperatures. Our study unambiguously demonstrates that a nonmetallic catalyst can catalyze CNT growth by thermal CVD while remaining in an oxidized state and provides new insight into the interactions between nanoparticulate metal oxides and carbon at elevated temperatures.

Mechanically robust and electrically conductive carbon nanotube foams

We describe the fabrication of ultralow-density carbon nanotube (CNT) foams that simultaneously exhibit high electrical conductivities and robust mechanical properties. Our approach utilizes carbon nanoparticles as a binder to crosslink randomly oriented bundles of single-walled CNTs. The resulting CNT foams are the stiffest low-density nanoporous solids reported and exhibit elastic behavior up to strains as large as ∼80%. The use of the carbon binder also allows bulk electrical conductivity to be maintained at low densities.

Supercapacitors Based on Three-Dimensional Hierarchical Graphene Aerogels with Periodic Macropores

Graphene is an atomically thin, two-dimensional (2D) carbon material that offers a unique combination of low density, exceptional mechanical properties, thermal stability, large surface area, and excellent electrical conductivity. Recent progress has resulted in macro-assemblies of graphene, such as bulk graphene aerogels for a variety of applications. However, these three-dimensional (3D) graphenes exhibit physicochemical property attenuation compared to their 2D building blocks because of one-fold composition and tortuous, stochastic porous networks. These limitations can be offset by developing a graphene composite material with an engineered porous architecture. Here, we report the fabrication of 3D periodic graphene composite aerogel microlattices for supercapacitor applications, via a 3D printing technique known as direct-ink writing. The key factor in developing these novel aerogels is creating an extrudable graphene oxide-based composite ink and modifying the 3D printing method to accommodate aerogel processing. The 3D-printed graphene composite aerogel (3D-GCA) electrodes are lightweight, highly conductive, and exhibit excellent electrochemical properties. In particular, the supercapacitors using these 3D-GCA electrodes with thicknesses on the order of millimeters display exceptional capacitive retention (ca. 90% from 0.5 to 10 A·g(-1)) and power densities (>4 kW·kg(-1)) that equal or exceed those of reported devices made with electrodes 10-100 times thinner. This work provides an example of how 3D-printed materials, such as graphene aerogels, can significantly expand the design space for fabricating high-performance and fully integrable energy storage devices optimized for a broad range of applications.

High Surface Area, sp2-Cross-Linked Three-Dimensional Graphene Monoliths

Developing three-dimensional (3D) graphene assemblies with properties similar to those individual graphene sheets is a promising strategy for graphene-based electrodes. Typically, the synthesis of 3D graphene assemblies relies on van der Waals forces for holding the graphene sheets together, resulting in bulk properties that do not reflect those reported for individual graphene sheets. Here, we report the use of sol-gel chemistry to introduce chemical bonding between the graphene sheets and control the bulk properties of graphene-based aerogels. Adjusting synthetic parameters allows a wide range of control over surface area, pore volume, and pore size, as well as the nature of the chemical cross-links (sp(2) vs sp(3)). The bulk properties of the graphene-based aerogels represent a significant step toward realizing the properties of individual graphene sheets in a 3D assembly with surface areas approaching the theoretical value of an individual sheet.

Synthesis and characterization of monolithic carbon aerogel nanocomposites containing double-walled carbon nanotubes.

We report the synthesis and characterization for the first examples of monolithic low-density carbon aerogel (CA) nanocomposites containing double-walled carbon nanotubes. The CA nancomposites were prepared by the sol-gel polymerization of resorcinol and formaldehyde in an aqueous surfactant-stabilized suspension of double-walled carbon nanotubes (DWNTs). The composite hydrogels were then dried with supercritical CO 2 and subsequently carbonized under an inert atmosphere to yield monolithic CA structures containing uniform dispersions of DWNTs. The microstructures and electrical conductivities of these CA nanocomposites were evaluated for different DWNT loadings. These materials exhibited high BET surface areas (>500 m (2)/g) and enhanced electrical conductivities relative to pristine CAs. The details of these results are discussed in comparison with theory and literature.

Macroscopic 3D nanographene with dynamically tunable bulk properties.

Polymer-derived, monolithic three-dimensional nanographene (3D-NG) bulk material with tunable properties is produced by a simple and inexpensive approach. The material is mass-producible, and combines chemical inertness and mechanical strength with a hierarchical porous architecture and a graphene-like surface area. This provides an opportunity to control its electron transport and mechanical properties dynamically by means of electrochemical-induced interfacial electric fields.

Ultralow Density, Monolithic WS2, MoS2, and MoS2/Graphene Aerogels

We describe the synthesis and characterization of monolithic, ultralow density WS2 and MoS2 aerogels, as well as a high surface area MoS2/graphene hybrid aerogel. The monolithic WS2 and MoS2 aerogels are prepared via thermal decomposition of freeze-dried ammonium thio-molybdate (ATM) and ammonium thio-tungstate (ATT) solutions, respectively. The densities of the pure dichalcogenide aerogels represent 0.4% and 0.5% of full density MoS2 and WS2, respectively, and can be tailored by simply changing the initial ATM or ATT concentrations. Similar processing in the presence of the graphene aerogel results in a hybrid structure with MoS2 sheets conformally coating the graphene scaffold. This layered motif produces a ∼50 wt % MoS2 aerogel with BET surface area of ∼700 m(2)/g and an electrical conductivity of 112 S/m. The MoS2/graphene aerogel shows promising results as a hydrogen evolution reaction catalyst with low onset potential (∼100 mV) and high current density (100 mA/cm(2) at 260 mV).