Lead-tin solder has been widely used as interconnection material in electronics packaging for a long time. In response to environmental legislation, the lead-tin alloys are being replaced with lead-free alloys and electrically conductive adhesives in consumer electronics. Lead-free solder usually require higher reflow temperatures than the traditional lead-tin alloys, which can cause die crack and board warpage in assembly process, thereby impacting the assembly yields. The high tin content in lead-free solder forms tin whiskers, which has the potential to cause short circuits failure. Conductive adhesives are an alternative to solder reflow processing, however, conductive adhesives require up to 80 wt% metal filler to ensure electrical and thermal conductivity. The high loading content degrades the mechanical properties of the polymer matrix and reduces the reliability and assembly yields when compared to soldered assemblies. Carbon nanotubes (CNTs) have ultra high aspect ratio as well as many novel properties. The high aspect ratio of CNTs makes them easy to form percolation at low loading and together with other novel properties make it possible to provide electrical and thermal conductivity for the polymer matrix while maintaining or even reinforcing the mechanical properties. Replacing the metal particles with CNTs in conductive adhesive compositions has the potential benefits of being lead free, low process temperature, corrosion resistant, electrically/thermally conductive, high mechanical strength and lightweight. In this paper, multiwall nanotubes (MWNTs) with different dimensions are mixed with epoxy. The relationships among MWNTs dimension, volume resistivity and thermal conductivity of the composite are characterized. Different loadings of CNTs, additives and mixing methods were used to achieve satisfying electrical and mechanical properties and pot life. Different assembly technologies such as pressure dispensing, screen and stencil printing are used to simplify the processing method and raise the assembly yields. Contact resistance, volume resistivity, high frequency performance, thermal conductivity and mechanical properties were measured and compared with metal filled conductive adhesive and traditional solder paste.

Extrapolating the properties of individual carbon nanotubes (CNTs) into macro-scale CNT materials using a continuous and cost effective process offers enormous potential for a variety of applications. The floating catalyst chemical vapour deposition (FCCVD) method discussed in this dissertation bridges the gap between generating nano- and macro-scale CNT material and has already been adopted by industry for exploitation. A deep understanding of the phenomena that occur within the FCCVD reactor and how to control the formation of the catalyst nanoparticles is, therefore, essential to producing a desired CNT product and successfully scaling up the FCCVD process. This dissertation connects information on the decomposition of reactants, axial catalyst nanoparticle dynamics and the morphology of the resultant CNTs and demonstrates how these factors are strongly related to the temperature and chemical availability of reactants within the reactor. For the first time, in-situ measurements of catalyst particle size distributions paired with reactant decomposition profiles and detailed axial SEM studies of formed CNT materials revealed specific temperature domains that have important implications for scaling up the FCCVD process. A novel observation was that the evaporation and re-condensation of catalyst nanoparticles results in the formation, disappearance and reformation of the nanoparticles along the reactor axis. The combined influences of pyrolytic carbon species and catalytic nanoparticles are shown to influence CNT aerogel formation. This work also examines the source of carbon in the formed CNTs and the location of aerogel formation. Axial measurements using isotopically-labelled methane (C13H4) demonstrate that carbon within all CNTs is primarily derived from CH4 rather than some of the early-forming CNTs being predominantly supplied with carbon from decomposed catalytic precursor components. Quantification of CNT production along the axis of the reactor dispels the notion that injection parameters influence CNT formation and shows that bulk CNT formation occurs near the reactor exit regardless of the carbon source (CH4, toluene or ethanol). By supplying carbon to different reactor locations, it was discovered that CNT aerogel formation will occur even when carbon is delivered near the exit of the reactor provided the carbon source reaches a temperature sufficient to induce pyrolysis (>1000°C). Furthermore, experimental studies that identify a new role of sulphur (S) in the CNT formation process are discussed in this work. Analogous to effects observed in other aerosol systems containing S, in the FCCVD reactor, S lowers the nucleation barrier of the catalyst nanoparticles and enhances not only CNT growth but catalyst particle formation itself. The new concept of critical catalyst mass concentration for CNT aerogel formation was identified by implementing the novel approach of completely decoupling catalyst particle formation from CNT aerogel production. Rather than aerogel formation being dependent on a critical particle number concentration and ideal sized catalyst nanoparticles at the entrance of the reaction furnace, it was identified that the important metric is instead a minimum critical catalyst mass concentration. Application of the principle using other catalyst precursors such as cobaltocene, with continuous CNT aerogel formation from cobalt based catalyst nanoparticles being reported for the first time, and iron-based nanoparticles from a spark generator, provides proof of the new principle’s robustness and ubiquity. In addition to the experimental studies above, theoretical studies have been carried out to understand the agglomeration occurring in a CNT aerosol. The agglomeration eventually leads to a gas phase synthesized CNT aerogel at the end of the reactor, which can be collected and spun continuously. The results of this work are not only scientifically interesting, they also provide a strong foundation for further research aimed at optimizing and controlling large-scale CNT reactors by modifying downstream dynamics.

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CO2 is a waste product from a number of human activities such as fossil fuel power generation, industrial manufacturing processes, and transport. The rising concentration of CO2 in the atmosphere is heating the planet’s surface via the well-established greenhouse effect; a mechanism for many irreversible climate change impacts. Coupled to this is the ever-increasing global pressure over the availability and access to fossil fuel reserves; the foundations of modern society. In recognition of this CO2 is gaining renewed interest as a carbon feedstock, a changing of attitude viewing it as an asset rather than waste. Carbon capture and utilisation (CCU) technologies are attempting to make use of it. However, little quantitative assessment work has been done to assessand verify such potentials. This thesis applies the principles and framework of the life cycle assessment (LCA) - environmental management tool to early stage CO2 utilisation laboratory processes. All processes employ engineered nanomaterials (ENM) to perform this function, a material class leading the way in the challenges of efficient and feasible CO2 chemistry. The LCA contribution in this thesis acts as a measuring and a guiding tool for technology developers, in the first instance to document the cradle-to-gate impacts of a number of formed ENMs. Appreciating the net environmental benefits of ENM uptake within society has yet to be wholly established, and the unavailability of data is recognised as a major factor. The work of this thesis will thus contribute to knowledge gaps, and be informative to wider community seeking to quantify technical performance benefits of ENMs in the context of net life cycle impact burdens. Finally the actual CCU processes are assessed, initially within the confines of the laboratory but further expanded for consideration at more industrially relevant scales. The potential for sound CCU performance were found achievable under best case conditions, with net GHG impact reductions over the life cycle, and the potential for lower impact carbon products, even carbon negative. However other environmental impacts such as ozone depletion, toxic emissions and the consumption of precious metalores are impacts that require consideration in the use of such technologies.

Carbon nanotubes possess various unique and interesting properties. They have very high thermal and electrical conductivities, high stiffness, mechanical strength, and optical properties. Due to these properties, CNTs are widely used materials in a variety of fields. It is used for biotechnological and biomedical applications, as chemical and biosensor, in energy storage and field emission transistor. Experimentally synthesized CNTs are generally found in bundle form due to the strong vander Waals (vdW) at-traction between the individual tubes. To use CNTs in real life applications, we often require specific nanotubes with particular characteristics. The nanotube bundle is a mixture of various chirality, diameters and electronic properties (metallic and semiconducting). Only thermal energy is not sufficient to disperse nanotubes from the bundle geometry overcoming the strong vdW attraction between nanotubes. The hydrophobic and insoluble nature of CNTs in the aqueous medium makes the dispersion of CNTs even more difficult. So, it is a big challenge to get single pristine nanotube from the bundle geometry. Many experimental and theoretical studies have addressed the problem of nanotube dispersion from the bundle geometry. Ultrasonic dispersing method is a widely used technique for this purpose where ultrasonic sound is applied to agitate particles in a system. Other methods include using different organic and inorganic solutions, various surfactant molecules, different polymers as dispersing agents. In this study we extend our e orts to develop some better methods and improved dispersing agents. In this thesis, we address the problem of CNT dispersion. To address this issue, we rst give a quantitative estimation of the effective interaction between nanotubes. Next, we introduce different polymers (ssDNA and dendrimers) as external agents and show that they help to overcome the strong adhesive interaction between CNTs and make nanotube dispersion possible from the bundle geometry. For all of the works presented in this thesis, we have used fully atomistic MD simulation and DFT level calculations. We study ssDNA-CNT complex using all-atom MD simulation and calculate various structural quantities to show the stability of ssDNA-CNT complex in aqueous medium. The adsorption of ssDNA bases on CNT surface is driven by - interaction between nucleic bases and CNT. Using the potential of mean forces (PMF) calculation, we study the binding strength of the polynucleotide ssDNA for poly A, T, G, and C with CNT of chirality (6,5). From the PMF calculation, we show the binding sequence to be A > T > C > G. Except for poly G, our result is in good agreement with earlier reported single molecule force spectroscopy results where the sequence of binding interaction was reported to be A > G > T > C. To explore how the interaction between two CNTs mod-i ed in presence of ssDNA between them, we perform PMF calculation between the two ssDNA-wrapped CNTs. The PMF shows the sequence of interaction strength between two ssDNA-wrapped CNTs for different nucleic bases to be T > A > C > G. Thus, from PMF calculations we show the poly T to have the highest dispersion efficiency, which is consistent with earlier reported experimental study. Our PMF calculation shows that poly C and poly G reduce the attraction between two CNTs drastically, whereas poly A and poly T make the interaction fully repulsive in nature. We also present microscopic pictures of the various binding conformations for ssDNA adsorbed on CNT surface. We also study the dendrimer-CNT complex for both the PAMAM and PETIM dendrimers of different generations at various protonation states and present microscopic pictures of the complex. We calculate PMF between two dendrimer wrapped CNTs and show that protonated and higher generations (G3, G4, and so forth) non-protonated PAMAM dendrimers can be used as e ective agents to disperse CNTs from bundle geometry. We also study the chirality dependence of PMF respectively. Finally, we study the interaction of mannose dendrimer with CNTs and show that the wrapping of mannose dendrimer can drive a metal to semiconducting transition in a metallic CNT. We attribute the carbon-carbon bond length assymetry in CNT due to the wrapping of mannose dendrimer as the reason for this band gap opening which leads to metal-semiconductor transition in CNT. Thus, the wrapping of mannose dendrimer on CNT can change its electronic properties and can be used in the band gap engineering of CNT in future nanotechnology. Thus, the works carried out here in this dissertation will help to address the problem of nanotube dispersion from the bundle geometry which will in turn help to use CNT for various applications in diverse fields.

Different carbon nanostructures have different properties and different applications. It is needed to synthesize good quality and also on large scale. From the point of industrial applications, highly productive and low cost synthesis method is very essential. Research has been done extensively on the intrinsic and individual properties of both single walled carbon nanotubes (SWCNTs) and multiwalled carbon nanotubes (MWC-NTs) in the range of nanometer to micrometer length scale. The important question is how the properties change beyond this length scale and if they are used in group in the form of an array instead of the individual carbon nanotubes (CNTs). Some applications require large current output, large energy production etc. For such kind of applications, it becomes essential to use CNTs in large number in the form of arrays or array, instead of using large numbers of CNTs in individual level. Future nanotechnology scope requires large scale application using the very rich intrinsic properties of the CNTs and nanomaterials. Keeping these problems and challenges in front, this thesis work is devoted to the research of the large scale synthesis of mm long MWCNTs, having different morphology and studies on various physical properties of MWCNTs in the form of arrays. Synthesis of mm long aligned and buckled MWCNTs have been reported for the first time. Generally buckled CNTs were obtained by compressing the straight CNTs. Apart from this, different morphologies like, aligned straight, helical or coiled CNTs are also synthesized. Resistance of the individual CNT increases with the increase in length. Resistance versus length of an array of CNT also shows similar behaviour. The thermal conductivity of CNT array is observed to decrease with the increase of array diameter (diameter �100 µm). There are few reports of the similar behaviour with the experiments done on small diameter CNT arrays (diameter �100 nm). From these observations, it seems that in the arrays of CNT, their intrinsic individual property is preserved though the magnitudes are different. The conductance measurements done on buckled CNT array by compressing it to apply uniaxial strain, shows the conductance oscillation. This conductance oscillation seems to be originating from the band gap change due to strain when the CNTs bend during compression. Recent research focuses on the arrays of CNT as they can carry large current of the order of several milliamperes that make the arrays suitable in nanoscale electronics and in controlling macroscopic devices such as light emitting diodes and electromotors. Regarding this aspect, a part of this thesis work is devoted on the application of CNT array to field effect transistor (FET) and study of thermoelectric power generation using CNT arrays. The entire thesis is based on the works discussed above. It has been organized as follows: Chapter 1 deals with introduction about the different carbon nanostructures and different synthesis methods. A brief introduction about the different current-voltage (IV) characteristics of SWCNTs and MWCNTs, length and diameter dependence and effect of the mode of contacts, are given. Some applications of the array of CNTs like buckling effect on compression, stretching of CNT into the form of rope, and conduction change on compression are discussed. Application of CNT as FET, as a thermometer, and thermoelectric effect of CNT are discussed. The electromechanical effect of CNT is also discussed briefly. Chapter 2 deals with experimental setup for synthesis of different morphologies of carbon nanostructures. The samples are characterized using common characterization techniques like, scanning electron microscopy (SEM), transmission electron microscopy (TEM) and Raman spectroscopy. A brief introduction about Raman Spectroscopy of CNT is given. Chapter 3 reports the unusual IV characteristics and breakdown of long CNT arrays. The current carrying ability and the threshold voltage as a function of array diameter are reported. The effect of the ambient like temperature and pressure are discussed. Chapter 4 deals with theoretical models to analyze the IV characteristics reported in Chapter 3. It has been shown that a set of classical equations are applicable to quantum structures and the band gap can be evaluated. Chapter 5 describes with application of CNT arrays as temperature sensors. It has been shown that CNT arrays of suitable diameters are used as temperature sensors after calibration. Chapter 6 reports the high current FET application of CNT arrays. Effects of temperature and ambient pressure are discussed. The type of the majority charge carrier is determined. Chapter 7 deals with application of CNT arrays as thermoelectric power generator to get large thermoelectric current. Effects of different array diameter are discussed. Modulation of thermoemf with gate voltage is discussed. The type of the majority charge carrier is determined. Chapter 8 reports the effect of compressive strain on buckled MWCNT arrays. Conductance is measured during the compression of the array. Quantum electromechanical conductance oscillation is observed. The structural changes are observed with SEM. Raman spectroscopic study supports the explanation of the effect. Chapter 9 provides the conclusion and overall summary of the thesis.

Carbon nanotubes (CNT) and graphene have been one of the noticeable research areas in science and technology. In recent years, the assembly of these carbon nanostructures is one of the most interesting topic to the scientific world due to its variety of applications from nano to macroscale. These bulk nanostructures to be applicable in shock absorbers, batteries, sensors, photodetectors, actuators, solar cells, fuel cells etc. The present work is motivated to study the detailed compressive behavior of three dimensional cellular assemblies of CNT and graphene. The CNT foams are synthesized by chemical vapor deposition method. It is interesting to study the compressive behavior of CNT foam in the presence external magnetic field applied perpendicular to CNT axis. The peak stress and energy absorption capability of CNT foam enhances by four and nearly two times in the presence of magnetic field as compared to the absence of the magnetic field. In the absence of magnetic field the deformation of CNT foam is obtained elastic, plateau and densification regions. Further CNT foam is loaded with iron oxide nanoparticles of diameter is ~ 40nm on the surface and detailed study of the compressive behavior of the foam by varying iron nanoparticles concentration. The peak stress and energy absorption capability of CNT foam initially decreases with increasing the intensity of the magnetic field, further increases the intensity of the magnetic field the maximum stress and energy absorption capability increases which is due to magnetic CNT and particles align in the direction of the magnetic field. CNT surfaces were further modified by fluid of different viscosities. The mechanical behavior of CNT foam filled with fluids of varying viscosities like 100%, 95% and 90% glycerol and silicone oil are 612, 237, 109 and 279 mPa-s respectively. The mechanical behavior of CNT foam depends on both the intensity of magnetic field and fluid viscosity. The non linear relation between peak stress of CNT and magnetic field intensity is σp(B, η) = σ0 ± α(B-B0) where σ0 is the peak stress at B = B0 , η is the fluid viscosity, parameter α depends on properties of the MR fluid and B0 is an optimum magnetic field for which peak stress is maximum or minimum depending on the fluid viscosity. Graphene is assembled into a three dimensional structure called graphene foam. The graphene foam is infiltrated with polymer and study the detailed compressive behavior of graphene foam and graphene foam/PDMS at different strains of 20, 40, 60 and 70%. The maximum stress and energy absorption capability of graphene foam/PDMS is six times higher than the graphene foam. Also the graphene foam/PDMS is highly stable and reversible for 100 cycles at strains of 30 and 50%. The mechanical behavior of CNT, graphene foam, CNT/PDMS and graphene foam/PDMS is compared. Among all the foams, graphene foam/PDMS has shown the highest elastic modulus as compared to other foams. This behavior can be attributed to the wrinkles formation during the growth of graphene and a coupling between PDMS and interfacial interactions of graphene foam. Therefore it suggests potential applications for dampers, cushions and electronic packaging. Furthermore, the interaction between nanoparticles and polymer in a novel architecture composed of PDMS and iron oxide nanoparticles is studied. The load bearing capacity of uniform composites enhanced by addition of nanoparticles, reaching to a maximum to 1.5 times of the PDMS upon addition of 5wt.% of nanoparticles, and then gradually decreased to 1/6th of PDMS upon addition of 20wt.% of nanoparticles. On the other hand, the load bearing capacity of architectured composites at high strains (≥40%) monotonically increased with addition of nanoparticles in the pillars.