Described is a method for ultrasonically spraying thin films of carbon nanotubes that have been suspended in organic solvents. Nanotubes were sonicated in N-methyl-2-pyrrolidone or N-cyclohexyl-2-pyrrolidone (CHP) and then sprayed onto a heated substrate using an ultrasonic spray nozzle. The solvent was quickly evaporated, leaving a thin film of randomly oriented nanotubes. Unlike other methods of spraying nanotube films, this does not require removal of surfactant after spraying and is compatible with creating films of functionalized nanotubes. Film thickness was controlled by the spray time and films were sprayed with thicknesses between 10 and 500 nm. Single-walled, multiwalled, and functionalized multiwalled nanotubes were sprayed. Transparent conducting thin films prepared by spraying single-walled carbon nanotubes dispersed in CHP demonstrated similar sheet resistance (for a given optical transmittance) as those prepared by spraying aqueous polymer-based dispersions that required postdeposition polymer removal.

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Sputtered amorphous carbon thin films were explored as corrosion resistant coatings on aluminum thin films to be incorporated into x-ray detector windows. The requirements for this application include high corrosion resistance, low intrinsic stress, high strains at failure, and high x-ray transmission. Low temperature sputtering was used because of its compatibility with the rest of the window fabrication process. Corrosion resistance was tested by exposure of carbon coated and uncoated Al thin films to humidity. Substrate curvature and bulge testing measurements were used to determine intrinsic stress and ultimate strain at failure. The composition and bonding of the carbon films were further characterized by electron energy loss spectroscopy, Raman spectroscopy, and carbon, hydrogen, and nitrogen elemental analyses. Samples had low compressive stress (down to.08 GPa), a high strain at failure (3%), and a low fraction of sp3 carbon–carbon bonds (less than 5%). The high breaking strain and excellent x-ray transmission of these sputtered carbon films indicate that they will work well as corrosion barriers in this application.