High Pressure High Temperature Consolidation of Carbon Nanotubes for Structural and Other Applications

Diamond Materials Incorporated (DMI) proposes to synthesize a new class of carbon-carbon composite, termed "Fullertubite". In conventional carbon-carbon ceramics, composite properties are controlled by the anisotropic properties of the carbon fibers. Fullertubite, synthesized from randomly oriented micron-sized carbon nanotubes, has the potential to overcome the anisotropic strength properties, while improving the toughness by crack deflection and crack branching. Moreover, carbon nanotubes are more oxidation resistant than other forms of fullerene derivatives and thus Fullertubite have potential for superior high temperature stability. Building upon our recent experiments on high pressure high temperature consolidation of C60 fullerenes, Fullertubite will be produced in our High Pressure High Temperature apparatus, by three-dimensional polymerization of carbon nanotubes at pressures of 2 GPa - 8 GPa, and temperatures up to 1600 degrees C. In Phase 1, Fullertubite synthesis will be demonstrated for small pellets (4mm o x 3mm thick), which will allow characterization of its physical, mechanical, thermal, electrical, and other properties that are pertinent to military and industrial applications. In Phase II, we will develop industrial scale methods of Fullertubite synthesis not only for structural materials but also for additional applications as warranted. In Phase II, we will also focus on methodologies to increase production, improve properties, and reduce cost. In Phase III, we will commercialize the technology.