IPA precursor bubbler assembly: Add 80 mL of isopropanol (IPA) to a 250 mL Erlenmeyer flask. Cut the stem of a wash bottle into two straight segments of roughly equal length. Push these stems into the holes of a two-hole rubber stopper. Attach a piece of plastic tubing to one of the stems such that the tubing is fully submerged in the IPA when the two-hole rubber stopper seals the Erlenmeyer flask. The N2 will be supplied to the bubbler via this stem, which is called the supply stem. The N2/IPA vapor above the IPA liquid will flow out of the bubbler through the other stem, which is called the exhaust stem. Seal the Erlenmeyer flask with the two-hole rubber stopper. Use a second piece of plastic tubing to connect the top of the supply stem to the nozzle of the N2 regulator as shown in Supplementary Figs. S1 and S2. It is important to use plastic tubing with inner diameter of approximately 6.4 mm (0.25 inches) throughout this procedure. Otherwise, the flow rates provided here will need to be adjusted to account for the difference in diameter. Warning: Consult the material safety data sheet for IPA before using this chemical.
Reaction chamber assembly: Secure a quartz tube that is approximately 41 cm (16 inches) in length and has an inner diameter of 13 mm and outer diameter of 15 mm to a ring stand so that its long axis is parallel to the ground. Adjust the height of the quartz tube so that the Meker burner can be positioned approximately 1 cm below the quartz tube. Push a 1 mL syringe equipped with a needle [18 gauge and length of 3.8 cm (1.5 inches)] into the open end of a piece of plastic tubing. Connect the other end of the plastic tubing to the exhaust straw of the IPA precursor bubbler. Fit a 1.25 cm rubber septum snugly into the quartz tube. Puncture the center of the septum with the needle so that most of the needle is inserted into the quartz tube. This connection is shown in Supplementary Fig. S3. It is critical that the septum fits tightly into the quartz tube so that no O2 or H2O from the air diffuses into the system during the reaction.
Insert the Ni foil into the open end of the quartz tube and place it > 10 cm from the end of the quartz tube. Push a 1 mL syringe equipped with a needle [18 gauge and length of 3.8 cm (1.5 inches)] into the open end of a piece of plastic tubing. Place the other end of the plastic tubing into a beaker filled with H2O, which is where the N2/IPA vapor will be exhausted. Fit a 1.25 cm rubber septum snugly into the open end of the quartz tube. Puncture the center of the septum with the needle so that most of the needle is inserted into the quartz tube. Ensure that the Ni foil is still positioned > 10 cm from the end of the quartz tube. If the Ni foil is too close to the needle, the needle will become hot during the graphene synthesis and the plastic syringe may melt.
Multiple experimental setups can be assembled in series or in parallel. In series, the quartz tubes are connected together so that the exhaust stream of an upstream experimental setup is the supply stream of a downstream experimental setup. In this configuration, each experimental setup receives the same stream of gas flow. Also, the H2O exhaust beaker is only needed after the most downstream experimental setup. The main advantage of connecting the setups in series is that no gas flow splitter is needed. The primary disadvantage of connecting the setups in series is that a leak in an upstream experimental setup will also introduce a leak into every setup located downstream, which detrimentally affects the graphene coverage and quality. Therefore, the successful synthesis of graphene in a downstream experimental setup critically depends on the construction of all setups that are located upstream.
On the other hand, in parallel, the gas stream is split to each system so that each experimental setup receives an independent gas stream. We recommend that the flow is split between the IPA precursor bubbler and the upstream end of each experimental system so that only one IPA precursor bubbler is needed to accommodate all setups. The main advantage of connecting the setups in parallel is that each tube receives its own gas stream; so this method is more likely to produce high-quality graphene than the series connection. The main disadvantage of connecting the setups in parallel is that gas flow splitters (crosses and/or tees) are needed. However, these items are only $0.44 apiece, as listed below.
Warning: Do not use a glass tube for the reaction chamber instead of a quartz tube because glass is less stable and less resistant to cracking at the high temperatures used during synthesis. Be careful when using sharp needles to avoid puncturing oneself and dispose of the needles properly.
Leak prevention: Wrap all connections with Parafilm to prevent diffusion of O2 and H2O from the air into the reaction vessel. These connections include the nozzle of the gas regulator with the plastic tubing, the plastic tubing with both the supply and exhaust stems, the two-hole rubber stopper with the Erlenmeyer flask, the plastic tubing with both syringes, and the septa with both ends of the quartz tube. Hose clamps can additionally be used at appropriate junctions to further prevent leaks.
Gas flow introduction: Now, introduce the N2 flow into the system with the gas flow regulator (Supplementary Fig. S1). Ensure that the N2 flow rate control dial is closed (turned completely clockwise). Open the N2 tank valve by turning the valve counterclockwise. The N2 tank pressure gauge reading should increase. If the gauge still reads 0 psi, the N2 tank is empty. In order to introduce N2 into the reaction chamber, slowly open the N2 flow rate control dial by turning it counterclockwise. The flow of N2 through the system is indicated by the presence of bubbles in the IPA precursor bubbler and in the H2O exhaust beaker. Adjust the flow rate control dial to maintain a flow rate of 3 bubbles/second. The flow rate can be measured by counting the number of bubbles through the IPA bubbler or H2O exhaust over a given time span. The flow rate measured in the IPA bubbler and in the H2O exhaust should be nearly equal. If they are not the same, there is a leak between the IPA bubbler and H2O exhaust that must be repaired before beginning the graphene synthesis. In order to repair leaks, ensure that all connections are tightly secured into position and apply more Parafilm to the connections.
Warning: Introduce the N2 flow gradually by slowly opening the N2 flow rate control dial to prevent the needles from expelling from the septa.
System purge: Purge the system with the N2/IPA flow for 5 min. During this time, ensure that the flow rate remains stable at > 3 bubbles/second. If it does not, adjust the flow rate with the flow rate control dial until the flow rate stabilizes. If the flow rate is < 1 bubble/second, the system will not be at a sufficient overpressure to prevent O2 and H2O from the air from diffusing into the system, which will oxidize the Ni foil and inhibit high-quality graphene growth. If a flow rate > 3 bubbles/second is used, it is less likely that O2 and H2O will diffuse into the system; however the multilayer graphene film will be thicker because more IPA precursor will be introduced.
H2O vapor desorption: After purging the system for 5 min and letting the gas flow rate stabilize, ignite the Meker burner. In order to achieve the maximum temperature, rotate the shaft of the burner such that the holes at the base of the burner are aligned. Quickly move the burner along the entire length of the quartz tube for several seconds to remove H2O adsorbed to the inside of the tube. This H2O desorption is observable by eye. While sweeping the flame, do not expose the Ni foil to the flame for more than 1 second to ensure that graphene growth is not initiated. Also, do not expose the ends of the quartz tube to the flame for more than 1 second to ensure that the needles to not overheat, which can melt the syringes.
Warning: Be careful when operating the Meker burner, which outputs a hotter flame than typical Bunsen burners. Never leave the flame unattended and locate the nearest fire extinguisher in advance.
Graphene synthesis: Once the H2O stops visibly desorbing from the quartz tube, place the flame of the Meker burner approximately 1 cm (the hottest part of the flame) directly under the Ni foil to begin the graphene synthesis. The Meker burner must be used because it is able to reach a sufficiently high temperature of 550-600 °C to ensure high-quality graphene growth. Typical Bunsen burners only reach 350-400 °C. Allow the reaction to proceed for 5-10 min. In order to terminate growth, extinguish the Meker burner by turning off its gas source. Allow the quartz tube to cool for 3-5 min. After the quartz tube has cooled, close the N2 tank valve by turning the valve clockwise to stop the gas flow. Close the flow rate control dial by turning the dial clockwise. Disassemble the setup and carefully remove the Ni foil, which should now be coated with graphene. The graphene-coated Ni foil should be grey, like in Fig. 2a of the main text. If it is a different color, such as red, green, yellow, or blue like in Fig. 3b of the main text, the Ni foil probably oxidized during the synthesis and graphene most likely did not grow. This oxidation is a result of a leak into the system, either due to a low N2 flow rate < 1 bubble/second or a poorly sealed apparatus.
The oxidation rate of graphene-coated Ni foil is compared with that of bare Ni foil to confirm the presence of graphene and to demonstrate the high impermeability of graphene. Graphene-coated Ni foil (Fig. 2a) and bare Ni foil (Fig. 3a) are placed in the quartz reaction tube, which is kept open to atmosphere. The samples are heated with the Meker burner to 550 °C. After 2-5 min, the flame is turned off and the samples are inspected. The bare Ni foil oxidizes rapidly, turning different colors as the oxide thickness increases, as shown in Fig. 3b, until eventually turning green as the oxide reaches a critical thickness. In contrast, the graphene-coated Ni foil remains grey (Fig. 3c), indicating that the underlying Ni foil is protected by the graphene and, therefore, oxidizes to a lesser extent. This high impermeability of graphene makes it an excellent diffusion barrier.
The reaction conditions provided in the detailed experimental procedure above consistently result in the growth of high-quality, continuous graphene that fully covers the entire Ni foil substrate. Other growth conditions were attempted in which the growth time, precursor concentration, catalyst type, flow rate, and carrier gas were changed independently. All growth conditions are summarized below.
Graphene transfer: In order to transfer the multilayer graphene film from the Ni foil to an insulating, optically transparent substrate, cut a square 4 cm2 piece of polyethylene terephthalate (PET) with scissors. Heat the PET to 95 ˚C on a hot place for 5 min. Trim approximately 1 mm off the edges of the graphene-coated Ni foil. Flatten the graphene-coated Ni foil between two glass microscope slides and then place it on one of the microscope slides. Place the hot PET on top of the graphene. Next, place the glass slide, graphene-coated Ni foil, and PET on top of the hot plate at 95˚C. Apply pressure to the PET/graphene-coated Ni foil stack by rolling a glass stirring rod over the PET for 5 min. Allow the stack to sit on the hot plate at 95 °C for another 5 min. Turn off the hotplate and cool the sample for 5 min. Remove the glass slide from the PET/graphene-coated Ni foil. Gently scratch the exposed side of the Ni foil to remove graphene from that side of the Ni foil. This allows the Ni etchant to reach the Ni foil more easily. Float the PET/graphene-coated Ni foil stack on 1.0 M FeCl3 to dissolve the Ni foil. After etching the Ni foil for several hours, the multilayer graphene film remains on PET. Remove the sample from FeCl3 and rinse the sample with H2O. Dry the sample with a cloth or stream of air. The graphene transferred on PET is shown in Fig. 3d of the main text
Warning: Consult the material safety data sheet for FeCl3 before using this chemical.
Electrical measurements: The electrical resistance of graphene and PET can be compared after transfer of the graphene to the insulating PET substrate. Place both of the multimeter probe tips on the PET substrate. The resistance should be > 106 Ohms. Then, place both of the probe tips spaced approximately 1 mm apart on the multilayer graphene. The resistance should be 1000-5000 Ohms, considerably less than that of the PET substrate. If the graphene resistance is high, press the probe tips more firmly into the graphene. Ensure that the probe tips are not touching each other during the measurement.