Using Mechanical Alloying to Create Bimetallic Catalysts for Vapor-Phase Carbon Nanofiber Synthesis

Carbon nanofibers were generated over bimetallic catalysts in an atmospheric pressure chemical vapor deposition (APCVD) reactor. Catalyst compositions of Fe 30 at%, Cu and Ni 30 at% and Cu were mechanically alloyed using high-energy ball milling over durations of 4, 8, 12, 16, and 20 h. The catalyst powders were then used to produce carbon nanofibers in ethylene and hydrogen (4:1) at temperatures of 500, 550, and 600 degrees C. The microstructures of the catalysts were characterized as a function of milling time as well as at deposition temperature. The corresponding carbon deposition rates were assessed and are correlated to the microstructural features of each catalyst. The milling process directly determines the performance of each catalyst toward carbon deposition, and both catalysts performed comparably to those made by traditional co-precipitation methods. Considerations in miscible and immiscible nanostructured alloy systems are discussed.