Scalable nanomanufacturing of 2D layered materials and their integration into nano-enabled systems

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This proposal outlines a research program on the scalable nanomanufacturing of 2D materials and their functional integration into systems and devices that benefit from nano-size scaling. 2D nanomaterials capture the essence of atomic-size effects, and can benefit a diverse range of applications from mechanical properties, electrical and thermal conductivities, high surface areas and unique quantum-mechanical effects. However, their full potential in everyday life is limited by the current methods of fabrication which compromise either quality or quantity. The proposed program seeks to address fundamental scientific and applied issues in production scaling of top-down processed 2D material systems by researching the recently conceived compressible flow exfoliation (CFE), which is a continuous and high-throughput method for mechanically exfoliating 2D layered materials using supersonic flows. The proposed research program seeks to elucidate the fundamental processing-structure-property relations regarding CFE that are necessary for any bench-to-floor transition. The approach will consist of (1) using theory and numerical tools, coupled with experimental observations to establish the exfoliation mechanism, (2) optimize the processing and post-processing conditions for fully continuous operations, (3) demonstrate feasible applications of CFE processed 2D nanomaterials in nano-enabled systems such as flexible electronics, thermal management and synthetic-nacre systems. Through this work, which will involve a total of 10 HQP (4 MS, 2 PhD and 4 UG), several existing knowledge gaps surrounding the (i) theory of 2D material fragmentation, (ii) effect of treatment time on 2D material quality, and (iii) continuous, rapid and environmentally friendly processing of 2D materials will be addressed. The promise of graphene and other 2D nanomaterials has not delivered thus far, because of a major disconnect between what's happening in the lab vs. the factory floor. A recent study (Kauling et al. 2018 in Advanced Materials) examined "graphene" from 60 suppliers and found that most were just expensive milled graphite and that on average only 10% of the product was 10 atomic layers or less. These purely commercial, smoke-and-mirror ventures are detracting from the fundamental R&D efforts that are still needed in scalable nanomanufacturing of 2D materials resulting in calls for developing standards for product qualification from organizations like International Organization of Standards (ISO) and the UK's National Physical Laboratory. The proposed research program on scalable nanomanufacturing of 2D materials and their integration into nano-enabled systems will rely on established as well as emerging concepts from 2D materials science, compressible gas dynamics, colloid surface science and composites design principles. It will benefit the Canadian natural resources and manufacturing sectors through the ensuing R&D and the skills and experience training of HQP.