The present invention includes carbon nanotubes whose hollow cores are 100% filled
with conductive filler. The carbon nanotubes are in uniform arrays on a conductive
substrate and are well-aligned and can be densely packed. The uniformity of the
carbon nanotube arrays is indicated by the uniform length and diameter of the carbon
nanotubes, both which vary from nanotube to nanotube on a given array by no more
than about 5%. The alignment of the carbon nanotubes is indicated by the perpendicular
growth of the nanotubes from the substrates which is achieved in part by the simultaneous
growth of the conductive filler within the hollow core of the nanotube and the
densely packed growth of the nanotubes. The present invention provides a densely
packed carbon nanotube growth where each nanotube is in contact with at least one
nearest-neighbor nanotube. The substrate is a conductive substrate coated with
a growth catalyst, and the conductive filler can be single crystals of carbide
formed by a solid state reaction between the substrate material and the growth
catalyst. The present invention further provides a method for making the filled
carbon nanotubes on the conductive substrates. The method includes the steps of
depositing a growth catalyst onto the conductive substrate as a prepared substrate,
creating a vacuum within a vessel which contains the prepared substrate, flowing
H2/inert (e.g. Ar) gas within the vessel to increase and maintain the pressure
within the vessel, increasing the temperature of the prepared substrate, and changing
the H2/Ar gas to ethylene gas such that the ethylene gas flows within the vessel.
Additionally, varying the density and separation of the catalyst particles on the
conductive substrate can be used to control the diameter of the nanotubes.