In-flight gas phase growth of metal/multi layer graphene core shell nanoparticles with controllable sizes

In this report, we present a general method for a continuous gas-phase synthesis of size-selected metal/multi layer graphene (MLG) core shell nanoparticles having a narrow size distribution of metal core and MLG shell for direct deposition onto any desired substrate kept under clean vacuum conditions. Evolution of MLG signature is clearly observed as the metal-carbon agglomerates get transformed to well defined metal/MLG core shell nanoparticles during their flight through the sintering zone. The growth takes place via an intermediate state of alloy nanoparticle (Pd-carbon) or composite nanoparticle (Cu-carbon), depending upon the carbon solubility in the metal and relative surface energy values. It has been also shown that metal/MLG nanoparticles can be converted to graphene shells. This study will have a large impact on how graphene or graphene based composite nanostructures can be grown and deposited in applications requiring controllable dimensions, varied substrate choice, large area and large scale depositions.