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Multigram quantities of Cu nanowires ca. 25 nm in diameter and mm in length have been produced by AC electrodeposition into porous aluminium oxide (PAO) templates. Multiple, large-area Al electrodes (5 6 11 cm or 10 6 25 cm) are anodized in parallel at 25.0 V in 0.3 M H 2 SO 4 (aq) using custom built baths. The pores are efficiently filled by applying 200 Hz sine waves at 10 V rms between the anodized Al and Cu plate counter electrodes immersed in a 0.50 M CuSO 4 (aq) solution. Dissolution of the PAO template in 0.6 M H 3 PO 4 to free the Cu nanowires results in significant coarsening of the nanowires, whereas dissolution of the PAO template in 1.0 M NaOH(aq) results in retention of the Cu nanowire diameters corresponding to the pore diameter of the PAO template. Liberated Cu nanowires were characterized by scanning electron microscopy, X-ray diffraction, and X-ray photoelectron spectroscopy.

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A scaleable synthesis of metal nanowires has been developed using ac electrodeposition into the pores of porous aluminum oxide (PAO) templates, through the resistive barrier layer. Gram quantities of high aspect-ratio Cu nanowires (25 nm in diameter by ∼20,000 nm in length) were liberated by dissolving the PAO film with sodium hydroxide solution. The agglomerated nanowires were dispersed in methanol by ultrasonication and collected by centrifugation or filtration. The nanowires were blended into amorphous polyamide by melt processing. The dispersion and percolation of the nanowires in the polymer was investigated by electron microscopy and conductivity measurements as a function of nanowire loading and processing route. Mechanical properties were evaluated by tensile testing of miniature dog bone specimens.