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The intrinsic properties of nanomaterials offer promise for technological revolutions in many fields, including transportation, soft robotics, and energy. Unfortunately, the exploitation of such properties in polymer nanocomposites is extremely challenging due to the lack of viable dispersion routes when the filler content is high. We usually face a dichotomy between the degree of nanofiller loading and the degree of dispersion (and, thus, performance) because dispersion quality decreases with loading. Here, we demonstrate a potentially scalable pressing-and-folding method (P & F), inspired by the art of croissant-making, to efficiently disperse ultrahigh loadings of nanofillers in polymer matrices. A desired nanofiller dispersion can be achieved simply by selecting a sufficient number of P & F cycles. Because of the fine microstructural control enabled by P & F, mechanical reinforcements close to the theoretical maximum and independent of nanofiller loading (up to 74 vol %) were obtained. We propose a universal model for the P & F dispersion process that is parametrized on an experimentally quantifiable " D factor". The model represents a general guideline for the optimization of nanocomposites with enhanced functionalities including sensing, heat management, and energy storage.

Graphene Nano-Sheets (GNS) with different lateral sizes (193, 373 and 1070 nm) were produced using liquid phase exfoliation and controlled centrifugation. Alumina-GNS (0.8 vol%) composites with different size GNS were consolidated using spark plasma sintering. The fracture toughness, hardness and elastic modulus of the composites decreased with increasing GNS size. Microstructural investigation of the composites suggested that their mechanical properties were directly related to: (1) average number of GNS present per unit volume in composite; and (2) relative size of GNS to alumina grains. Small size GNS resulted in a 35% improvement of fracture toughness of alumina-GNS composite. The mechanism of crack propagation changed as the size of the GNS increased. The smaller size GNS produced various toughening mechanisms, while the larger size GNS, with similar size to the alumina grains, resulted in grain boundary sliding. The composite with larger size GNS was machinable using ordinary tungsten carbide drill bits. [ABSTRACT FROM AUTHOR]

The effects of hot-pressing (HP) and spark plasma sintering (SPS) methods on the grain size, microstructural features, and mechanical behaviour of graphene nanoplatelet/carbon nanotubes (GNTs) reinforced Al 2 O 3 nanocomposites were comprehensively studied. Different graphene nanoplatelet to carbon nanotube ratios were selected as the overall reinforcement content of composites prepared using HP and SPS. Highly densified samples (>98%) were obtained at 1650 °C under 40 MPa in Ar atmosphere, with dwell times of 1 h and 10 min for HP and SPS respectively. Both types of sample showed a mixture of inter- and transgranular fracture behaviour. A 50% grain size reduction was observed for samples prepared by HP compared to SPS samples. Both types of samples achieved a high flexural strength and fracture toughness of >400 MPa and 5.5 MPa m 1/2 , whilst SPS samples peaked at relatively lower GNT contents than those for the HP samples. Based on analyses of the morphology, grain sizes and fracture mode, similar toughening mechanisms for both types of sample were observed, involving the complex characteristics of the combined GNT fillers. [ABSTRACT FROM AUTHOR]

Graphene nano-platelets (GNP) were synthesised using a liquid phase exfoliation method and then used to produce well dispersed silica-GNP composites. The tribological properties of the silica-GNP composites with different vol% GNP loading were investigated. The wear behaviour at room temperature was studied using a ball on disc technique with alumina and borosilicate (BS) balls as the tribological counterpart. In the case of alumina balls, GNP above a critical concentration decreased the coefficient of friction of the composite by ~20% while increasing the wear resistance of the composite by ~5.5 times. In the case of using BS balls there was an improvement of ~8.5 times in the wear resistance while the coefficient of friction did not change. In both cases a percolating network of GNP above a critical concentration provided a lubricating effect to the silica matrix, resulting in a significant improvement in the tribological properties of the nano-composites. The extent of damage to GNP during tribology testing was quantified using Raman spectroscopy. [ABSTRACT FROM AUTHOR]

Well dispersed 45S5 Bioglass (BG)-graphene nanoplatelets (GNP) composites were prepared after optimising the processing conditions. Fully dense BG nanocomposites with GNP loading of 1, 3 and 5 vol% were consolidated using Spark plasma sintering (SPS). SPS avoided any structural damage of GNP as confirmed using Raman spectroscopy. GNP increased the viscosity of BG-GNP composites resulting in an increase in the sintering temperature by ~50 °C compared to pure BG. Electrical conductivity of BG-GNP composites increased with increasing concentration of GNP. The highest conductivity of 13 S/m was observed for BG-GNP (5 vol%) composite which is ~9 orders of magnitude higher compared to pure BG. For both BG and BG-GNP composites, in vitro bioactivity testing was done using simulated body fluid for 1 and 3 days. XRD confirmed the formation of hydroxyapatite for BG and BG-GNP composites with cauliflower structures forming on top of the nano-composites surface. GNP increased the electrical conductivity of BG-GNP composites without affecting the bioactivity thus opening the possibility to fabricate bioactive and electrically conductive scaffolds for bone tissue engineering. [ABSTRACT FROM AUTHOR]

Abstract: Graphene was prepared using liquid phase exfoliation and dispersed in an alumina matrix using an ultrasonication and powder processing route. Al2O3–graphene composites with up to 5vol% content were densified (>99%) using SPS. The fracture toughness of the material increased by 40% with the addition of only 0.8vol% graphene. However for higher graphene contents the improvement in fracture toughness was limited. Graphene changed the mechanism of crack propagation for the alumina matrix from inter-granular to trans-granular. The formation of an inter-connecting graphene network promoted easy fracture for concentration ⩾2vol%. Elastic modulus remained nearly constant for up to 2vol% and decreased significantly for 5vol% due to the formation of the inter-connecting graphene network. Fracture toughness measured with the indentation and chevron notch methods were consistent up to 2vol% and at 5vol% the percolating network of graphene resulted in easy crack propagation with significant discrepancy between the results for the two methods. [Copyright &y& Elsevier]

Abstract: Liquid exfoliation of graphene generally results in flakes with lateral size of one micron or less on average, too small for many applications. In this paper we describe a method to separate an existing dispersion with mean flake length of ∼1μm into fractions, each with different mean flake size. The initial dispersion is centrifuged at a high centrifugation rate, separating small flakes in the supernatant from large flakes in the sediment. Redispersion of the sediment, followed by successive centrifugation, separation and redispersion cycles can be used to separate the flakes by size so long as the centrifugation rate is decreased with each cycle. This procedure results in a range of dispersions with mean flake length varying from 1μm for the highest final centrifugation rate to 3.5μm for the sample whose final centrifugation rate was 500rpm. [Copyright &y& Elsevier]