Graphene and Composite Materials
Graphene and Composite Materials - Stronger Together
This presentation will;
Describe the type and characteristics of the most common forms of graphene used in composite materials.
Provide examples of how graphene is being used in composite materials and actual products.
Graphene Enhanced Composites And Plastics
Graphene and Composite Materials
Graphene and Composite Materials
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About
Graphene and Composite Materials
Types of Graphene Materials Used in Composites
Forms of Graphene
Graphene and Composite Materials
Forms of Graphene
Graphene is a two dimensional (i.e. one atom thick) planar sheet of sp²-bonded carbon atoms in a dense honeycomb shaped crystal lattice.
Graphene has extraordinary material properties including ultimate tensile strength of 130 gigapascals, electron mobility of 15,000 cm2·V−1·s−1, thermal conductivity between 2000–4000 W m−1K−1 and optical transparency of 97.7%. (Eric Pop, 2012) (Sheehy DE, 2009)
ISO/TS 80004-13:2017(en) Nanotechnologies — Vocabulary — Part 13: Graphene and related two-dimensional (2D) materials. Recognizes material up to and including 10 carbon layers as “graphene”.
Definitions
Graphene and Composite Materials
Forms of Graphene
Graphene production methods can be classified broadly as “Top Down” and “Bottom Up”.
“Top Down” methods start with a feedstock material such as graphite and through various methods (physical, electrical, chemical, etc.) exfoliate individual layers of carbon.
“Bottom Up” methods start with a carbon feedstock such as methane gas that under controlled conditions (such as Chemical Vapor Deposition-CVD) is deposited on a substrate material (such as copper) in single or multiple layers.
Production
Graphene and Composite Materials
Forms of Graphene
A wide range of materials in the commercial market are currently referred to as “graphene”.
Graphene Materials
Number of Carbon Layers Description
1 CVD, Mono-layer or “Pristine” Graphene
1 - 3 Very Few Layer Graphene (vFLG)
2 - 5 Few Layer Graphene (FLG)
2 - 10 Multi-Layer Graphene (MLG)
> 10 Exfoliated graphite or “Graphene nanoplatelets” (GNP)
Graphene and Composite Materials
Forms of Graphene
Type CarbonLayers Properties/Applications Typicalcommercialcost($/KG) Commerciallyavailable
EpitaxialCVD 1-2 Conductive/almostTransparent/ITO?
Highendelectronics Upto$500,000/m²CVDsystems-Scaleup?Cost!ITO?
FLG 3-10 Conductor/flexible/veryhighsurfacearea/Sensors $100-2,000 Yes-consistency?
Processibility?
MLG 11-20 Composites/Inksandcoatings/Lubricants/Printing $50-1,500 Yes-variableproduct
today!
GO variousInsulator?AmorphousHydrophillic-dispersions
Defectsandvoids.Cement$50-2,000 InPart-stillevolvingbut
growing
GraphiteusedinGNPproduction 50+ Lubricants/Refactories/brakes/
Engineeringmaterials $1-20 Establishedfor150yearsApprox.1mtonnespa
Graphene and Composite Materials
Forms of Graphene
In addition to the number of carbon layers, additional characteristics define the material. Graphene Oxide (GO) - a compound of carbon, oxygen and hydrogen (typically approx. 65% carbon / 35% oxygen by weight).
Reduced Graphene Oxide (rGO) - Graphene Oxide in which removes much of the oxygen content resulting in approximately 95% carbon by weight.
Graphene Powder, Solution or Paste - Graphene material can be prepared in various physical forms including as a dry (usually black) powder, in solution (e.g. water or alcohol) or in a paste form (often as a dull reddish brown color).
Graphene Nano Platelets (GNPs) - GNPs typically have thickness of between 1 nm to 3 nm and lateral dimensions ranging from approximately 100 nm to 100 µm.
Functionalized Graphene - Chemical functionalization (adding specific elements to the surface of the graphene) is important in many applications where untreated graphene would be difficult to work with.
Graphene Materials
Graphene and Composite Materials
Sample Graphene Dispersion Routes
Graphene
Functionalization Functionalized Graphene
Solvent mixing with Plasticizer
Mechanical mixing with Plasticizer
Graphene / Plasticizer Solution
Graphene / Plasticizer
MasterbatchSolvent Removal
Compounding with Rubber
Graphene / Rubber Nano-composite
Dispersion with Surfactants
Graphene Liquid Premix Compounding into Polymer
Graphene Composite
Graphene / Plasticizer
MasterbatchCompounding with
RubberGraphene / Rubber
Nano-composite
Sources: Fullerex Ltd. and Cealtech Inc.
Dispersion into Monomer
Dispersion into ResinFunctionalized
Graphene Resin Masterbatch
Functionalized Graphene Monomer
Polymerization
CompoundingGraphene Composite
Graphene Composite
Graphene and Composite Materials
Forms of Graphene and “Quality”
There is widespread confusion about the definition of “Quality Graphene”.
Material that is not suitable for one application may be ideal for another.
Graphene “defects” may actually enhance the efficacy of the material for a particular application.
There is no such thing as a reference material for graphene at this time.
Because load factors can be quite low, the price of the material is not the most significant factor when selecting source material.
The primary factor is in selecting a trusted and competent supplier of the material that understands your application areas.
Graphene and Composite Materials
Examples of Graphene Enhanced Composites
and Applications
Graphene Enhanced Composites
Graphene and Composite Materials
Graphene Enhanced Composites
Of the more than 40 major application verticals for graphene, ‘Composites’ form the largest single application area.
Composites
Graphene and Composite Materials
Composite Application Areas
Graphene can be used to enhance performance in a wide range of applications;
Automotive
Rubber
Plastics
Aerospace
3D printing
Coatings and Barriers
Polymers and Epoxies
Carbon Fibre Reinforced Polymer (CFRP)
Sports Equipment
Graphene and Composite Materials
Material Performance Characteristics
Graphene is used to provide enhanced performance;
Performance Improvement
Electrical Conductivity
Thermal Managment
UV Protection
Longer Wear
Anti-Static
Weight Reduction
Robustness
Mechanical Reinforcement
Flexibility
Barrier Properties
Sensors (Enabling self monitoring)
Graphene and Composite Materials
Graphene Application Examples
Partnering with the Callaway golf company, XG Science’s GNP’s are used in the development of a new golf ball designed to improve performance.Sports
Graphene-infused Dual SoftFast Core maximizes compression energy while minimizing driver-spin and promoting high launch for long distance
Softer golf balls compress easier on off center hits for distance all over the face
"We've innovated at every layer, starting with our groundbreaking new Graphene Dual SoftFast Core. The result is an extremely fast and soft-feeling ball that promotes high-launch and low spin off the tee for long distance, and incredible shot-stopping spin around the green.” – Dr. Alan Hocknell, SVP, R&D, Callaway Golf
Graphene and Composite Materials
Graphene Application Examples
FORD MOTOR CO.
Graphene will be used under the hood in Ford vehicles, a first in automotive.
Ford, Eagle Industries and XG Sciences have found a way to use a very small amount of graphene while achieving major property improvements – more lightweight, better heat conductivity and noise reduction.
In vehicles, graphene will act like a pair of super-powered, noise cancelling headphones, reducing sound inside the cabin and creating a quieter ride
Graphene-Enhanced Materials
Graphene and Composite Materials
Graphene Application Examples
AutomotiveFormulated to amplify the mechanical performance of both rigid and flexible PU foams
Produces stronger foams and reduces heat distortion
Can be used in a wider variety of applications due to increased heat deflection temperature
Enables lightweighting
Improved compression strength by 20%
Improved NVH (noise & vibration) by 17%Engin Covers
for thermal management
Graphene-Enhanced Polyurethane Foam
Graphene and Composite Materials
Graphene Application Examples
Versarien, an advanced materials engineering group, based in Cheltenham, UK, partnered with Bromley Technologies Ltd, from Rotherham, UK, to create a bronze medal winning skeleton sled for British Olympian Dominic Parsons. (FEB 2018)
Versarien and Composites used in the Olympics
Dr Kristan Bromley, CEO and innovation director of Bromley Technologies Ltd, says:
“Graphene-enhanced composites enable the structural properties of sports products to be pushed to new levels. In particular, they allow increased strength-to-weight ratio and tougher impact properties to be achieved over conventional advanced composite materials. In elite sports where small margins often define winning performances, these enhancements can make the difference between winning and losing.”
Graphene and Composite Materials
Graphene Application Examples
Graphene enhanced resin automotive body panel developed in collaboration with the UK supercar company, BAC, the team responsible for the award-winning BAC Mono single-seat car.
Haydale Composite Solutions (HCS)
The graphene-enhanced resin is stronger than traditional materials, which has enabled the reduction in the amount of fibers in the composite material.
Approximately 20% reductions in mass can improve performance and fuel economy in vehicles.
Graphene and Composite Materials
Graphene Application Examples
Haydale Composite Solutions produced graphene-enhanced electrically-conductive carbon fibre-reinforced composite materials (CFRP).
The objective was to provide improved resistance to damage from a severe lightning-strike event on critical aircraft parts.
Carbon fibre-reinforced composite (CFRP)
Graphene and Composite Materials
Graphene Application Examples
Test results, untreated versus graphene enhanced material.
Figure1:BackfaceofunmodifiedpanelaFerlightningstrikeshowingpunch-through
Figure2:BackfaceofHaydale-modifiedpanelsaFerlightningstrikeshowingnovisibledamage
Carbon fibre-reinforced composite (CFRP)
Graphene and Composite Materials
Graphene Application Examples
Carbon fibre-reinforced composite (CFRP)600% increase in through-thickness electrical conductivity of laminates with scope to increase by several orders of magnitude.
Strength properties equivalent or better than control material.
Demonstrator produced proving manufacturing and demonstrating a typical Lightning strike zone 2/3 application.
Potential for the reduction/elimination of parasitic mass (copper mesh) leading to lower manufacturing costs and mass saved.
Other areas of application:
EMC and RF Shielding application such as electronic enclosures
Anti-static, aircraft ducting and piping, interior
Most applications using CFRP/GRP that need metal coatings for reflectivity/conductivity
Graphene and Composite Materials
Graphene Application Examples
Potential Benefits (While maintaining same structural performance)
Reduced number of plies
Lighter weight
Lower material cost
Reduced process cost—less laminating time
Lower component cost
Results in overall lower cost composite materials for equivalent performance metrics.
Graphene and Composite Materials
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