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The design and necessity of corrosion-resisting nanocarbon nanocomposites have been investigated for cutting-edge aerospace applications. In this regard, nanocarbon nanofillers, especially carbon nanotubes, graphene, nanodiamond, etc. have been used to fill in various polymeric matrices (thermosets, thermoplastics, and conducting polymers) to develop anti-rusting space-related nanocomposites. This review fundamentally emphases the design, anti-corrosion properties, and application of polymer/nanocarbon nanocomposites for the space sector. An electron-conducting network is created in the polymers with nanocarbon dispersion to assist in charge transportation, and thus in the polymers’ corrosion resistance features. The corrosion resistance mechanism depends upon the formation of tortuous diffusion pathways due to nanofiller arrangement in the matrices. Moreover, matrix–nanofiller interactions and interface formation play an important role in enhancing the corrosion protection properties. The anticorrosion nanocomposites were tested for their adhesion, contact angle, and impedance properties, and NaCl tests and scratch tests were carried out. Among the polymers, epoxy was found to be superior corrosion-resisting polymer, relative to the thermoplastic polymers in these nanocomposites. Among the carbon nanotubes, graphene, and nanodiamond, the carbon nanotube with a loading of up to 7 wt.% in the epoxy matrix was desirable for corrosion resistance. On the other hand, graphene contents of up to 1 wt.% and nanodiamond contents of 0.2–0.4 wt.% were desirable to enhance the corrosion resistance of the epoxy matrix. The impedance, anticorrosion, and adhesion properties of epoxy nanocomposites were found to be better than those of the thermoplastic materials. Despite the success of nanocarbon nanocomposites in aerospace applications, thorough research efforts are still needed to design high-performance anti-rusting materials to completely replace the use of metal components in the aerospace industry.

This article fundamentally reviews progress in the design and manufacturing of three-dimensional (3D) graphene-based nanocomposites for technical applications. The 3D graphene nanostructures have been manufactured using techniques like the template method, chemical vapor deposition, sol-gel, freeze-drying, hydrothermal technique, and other approaches. The nanofoam has been reinforced in polymers to achieve superior structural, morphological, and physical characteristics of the ensuing polymer/graphene nanofoam nanocomposites. The polymer/graphene nanofoam nanocomposites have been manufactured using the approaches like direct template method, in situ technique, infiltration process, and other methods. The 3D nanofoam- and polymer-based nanostructures have shown high specific surface area, suppleness, electron transport, thermal conduction, mechanical resilience, and other physical properties. The technical applications of hierarchical graphene nanofoams have been observed in the fields of radiation shielding, solar cells, supercapacitors, fuel cells, and other applications.

Recently, low-emissivity paint has gained more importance than commercial paints. Low emissivity (Low-E) Paint also termed as a coating for radiation control, in which the emissivity of radiations of longer waves are reduced dramatically (i.e., the emissivity of commercially available paint is 0.9) by imparting low emissivity particles in the base paint but not suitable to reduce near-infrared radiation. Commercially available paints as of today have minimum of 0.7 emissivity and it does not give any significant energy saving. The low emissivity property of paint makes it particularly suitable for reducing the radiative heat exchange in many domestic applications i.e., home electronics, building construction components, roof surfaces, heat storage tanks, and pipes, etc in result, low power required to heat or cool the building in respective whether conditions. In this work, different samples of white paint were prepared in the lab by using a low shear mixer (mechanical stirrer) under very controlled conditions and studied the results of dry paint films to reduce the thermal emissivity then commercially available paint. Then we investigate the drying time of the wet paint films and analyze thermal heat into visible light through thermal imaging camera, Crosshatch, and IR transmission. We also studied the emissivity through ET-100 and aging stability through a weather-o-meter instrument, which investigated that emissivity value achieved in the range of 0.4–0.6 than commercial paints. The results showed that paint exhibits an acceptable aesthetic emissivity value of ∼0.60. It was calculated theoretically that by the use of this novel Low-E paint, annually about 20%–25% less energy will be consumed in building for cooling or heating.

Electromagnetic interference is considered a serious threat to electrical devices, the environment, and human beings. In this regard, various shielding materials have been developed and investigated. Graphene is a two-dimensional, one-atom-thick nanocarbon nanomaterial. It possesses several remarkable structural and physical features, including transparency, electron conductivity, heat stability, mechanical properties, etc. Consequently, it has been used as an effective reinforcement to enhance electrical conductivity, dielectric properties, permittivity, and electromagnetic interference shielding characteristics. This is an overview of the utilization and efficacy of state-of-the-art graphene-derived nanocomposites for radiation shielding. The polymeric matrices discussed here include conducting polymers, thermoplastic polymers, as well as thermosets, for which the physical and electromagnetic interference shielding characteristics depend upon polymer/graphene interactions and interface formation. Improved graphene dispersion has been observed due to electrostatic, van der Waals, π-π stacking, or covalent interactions in the matrix nanofiller. Accordingly, low percolation thresholds and excellent electrical conductivity have been achieved with nanocomposites, offering enhanced shielding performance. Graphene has been filled in matrices like polyaniline, polythiophene, poly(methyl methacrylate), polyethylene, epoxy, and other polymers for the formation of radiation shielding nanocomposites. This process has been shown to improve the electromagnetic radiation shielding effectiveness. The future of graphene-based nanocomposites in this field relies on the design and facile processing of novel nanocomposites, as well as overcoming the remaining challenges in this field.

Research on polymer nanocomposite nanofibers has seen remarkable growth over the past several years. One of the main driving forces for this progress is the increasing applicability of polymer nanocomposite nanofibers for technological applications. This review basically aims to present the current state of manufacturing polymer/graphene nanofiber nanocomposites, using appropriate techniques. Consequently, various conducting and thermoplastic polymers have been processed with graphene nano-reinforcement to fabricate the nanocomposite nanofibers. Moreover, numerous methods have been adopted for the fabrication of polymer/graphene nanocomposites and nanofibers including interfacial polymerization, phase separation, freeze drying, template synthesis, drawing techniques, etc. For the formation of polymer/graphene nanocomposite nanofibers, electrospinning can be preferable due to various advantages such as the need for simple equipment, control over morphology, and superior properties of the obtained material. The techniques such as solution processing, melt spinning, and spin coating have also been used to manufacture nanofibers. Here, the choice of manufacturing techniques and parameters affects the final nanofiber morphology, texture, and properties. The manufactured nanocomposite nanofibers have been examined for exceptional structural, microstructure, thermal, and other physical properties. Moreover, the properties of polymer/graphene nanofiber rely on the graphene content, dispersion, and matrix–nanofiller interactions. The potential of polymer/graphene nanocomposite nanofibers has been investigated for radiation shielding, supercapacitors, membranes, and the biomedical field. Hence, this review explains the literature-driven significance of incorporating graphene in polymeric nanofibers. Conclusively, most of the studies focused on the electrospinning technique to design polymer/graphene nanofibers. Future research in this field may lead to advanced innovations in the design and technical applications of nanocomposite nanofibers. To the best of our knowledge, research reports are available on this topic; however, the stated literature is not in a compiled and updated form. Therefore, field researchers may encounter challenges in achieving future advancements in the area of graphene-based nanocomposite nanofibers without first consulting the recent literature, such as an assembled review, to gain necessary insights, etc. Consequently, this state-of-the-art review explores the manufacturing, properties, and potential of polymer/graphene nanocomposite nanofibers.

Among conducting polymers, polythiophene has gained an important stance due to its remarkable physical features. Graphene is a unique, two-dimensional, nanocarbon nanomaterial. As in other polymers, graphene has been reinforced in polythiophene to form advanced nanocomposites. This comprehensive review covers the design, essential features, and methodological potential of significant polythiophene and graphene-derived nanocomposites. In this context, various facile approaches, such as in situ processing, the solution method, and analogous simplistic means, have been applied. Consequently, polythiophene/graphene nanocomposites have been investigated for their notable electron conductivity, heat conduction, mechanical robustness, morphological profile, and other outstanding properties. Studies have revealed that graphene dispersion and interactions with the polythiophene matrix are responsible for enhancing the overall characteristics of nanocomposites. Fine graphene nanoparticle dispersal and linking with the matrix have led to several indispensable technical applications of these nanocomposites, such as supercapacitors, solar cells, sensors, and related devices. Further research on graphene nanocomposites with polythiophene may lead to remarkable achievements for advanced engineering and device-related materials.

Polyurethane is a multipurpose polymer with indispensable physical characteristics and technical uses, such as films/coatings, fibers, and foams. The inclusion of nanoparticles in the polyurethane matrix has further enhanced the properties and potential of this important polymer. Research in this field has led to the design and exploration of polyurethane foams and polyurethane nanocomposite foams. This review article reflects vital aspects related to the fabrication, features, and applications of polyurethane nanocomposite foams. High-performance nanocellular polyurethanes have been produced using carbon nanoparticles such as graphene and carbon nanotubes. Enhancing the amounts of nanofillers led to overall improved nanocomposite foam features and performances. Subsequently, polyurethane nanocomposite foams showed exceptional morphology, electrical conductivity, mechanical strength, thermal stability, and other physical properties. Consequently, multifunctional applications of polyurethane nanocomposite foams have been observed in shape memory, electromagnetic interference shielding, and biomedical applications.

Among nanocomposite materials, multifunctional polymer nanocomposites have prompted important innovations in the field of sensing technology. Polymer-based nanocomposites have been successfully utilized to design high-tech sensors. Thus, conductive, thermoplast, or elastomeric, as well as natural polymers have been applied. Carbon nanoparticles as well as inorganic nanoparticles, such as metal nanoparticles or metal oxides, have reinforced polymer matrices for sensor fabrication. The sensing features and performances rely on the interactions between the nanocomposites and analytes like gases, ions, chemicals, biological species, and others. The multifunctional nanocomposite-derived sensors possess superior durability, electrical conductivity, sensitivity, selectivity, and responsiveness, compared with neat polymers and other nanomaterials. Due to the importance of polymeric nanocomposite for sensors, this novel overview has been expanded, focusing on nanocomposites based on conductive/non-conductive polymers filled with the nanocarbon/inorganic nanofillers. To the best of our knowledge, this article is innovative in its framework and the literature covered regarding the design, features, physical properties, and the sensing potential of multifunctional nanomaterials. Explicitly, the nanocomposites have been assessed for their strain-sensing, gas-sensing, bio-sensing, and chemical-sensing applications. Here, analyte recognition by nanocomposite sensors have been found to rely on factors such as nanocomposite design, polymer type, nanofiller type, nanofiller content, matrix–nanofiller interactions, interface effects, and processing method used. In addition, the interactions between a nanocomposite and analyte molecules are defined by high sensitivity, selectivity, and response time, as well as the sensing mechanism of the sensors. All these factors have led to the high-tech sensing applications of advanced nanocomposite-based sensors. In the future, comprehensive attempts regarding the innovative design, sensing mechanism, and the performance of progressive multifunctional nanocomposites may lead to better the strain-sensing, gas/ion-sensing, and chemical-sensing of analyte species for technical purposes.

This review mainly addresses applications of polymer/graphene nanocomposites in certain significant energy storage and conversion devices such as supercapacitors, Li-ion batteries, and fuel cells. Graphene has achieved an indispensable position among carbon nanomaterials owing to its inimitable structure and features. Graphene and its nanocomposites have been recognized for providing a high surface area, electron conductivity, capacitance, energy density, charge–discharge, cyclic stability, power conversion efficiency, and other advanced features in efficient energy devices. Furthermore, graphene-containing nanocomposites have superior microstructure, mechanical robustness, and heat constancy characteristics. Thus, this state-of-the-art article offers comprehensive coverage on designing, processing, and applying graphene-based nanoarchitectures in high-performance energy storage and conversion devices. Despite the essential features of graphene-derived nanocomposites, several challenges need to be overcome to attain advanced device performance.

Fuel cell efficiency can be improved by using progressive electrodes and electrolytes. Green nanomaterials and green technologies have been explored for the manufacturing of high-performance electrode and electrolyte materials for fuel cells. Platinum-based electrodes have been replaced with green materials and nanocomposites using green fabrication approaches to attain environmentally friendly fuel cells. In this regard, ecological and sustainable electrode- and electrolyte-based membrane electrode assemblies have also been designed. Moreover, green nanocomposites have been applied to form the fuel cell electrolyte membranes. Among fuel cells, microbial fuel cells have gained research attention for the incorporation of green and sustainable materials. Hence, this review essentially focuses on the potential of green nanocomposites as fuel cell electrode and electrolyte materials and application of green synthesis techniques to attain these materials. The design of and interactions with nanocomposites have led to synergistic effects on the morphology, impedance, resistance, power density, current density, electrochemical features, proton conductivity, and overall efficiency. Moreover, we deliberate the future significance and challenges of the application of green nanocomposites in electrodes and electrolytes to attain efficient fuel cells.

Graphene is a unique nanocarbon nanostructure, which has been frequently used to form nanocomposites. Green-synthesized graphene has been focused due to environmentally friendly requirements in recent technological sectors. A very important application of green-synthesized graphene-based nanocomposite has been observed in energy storage devices. This state-of-the-art review highlights design, features, and advanced functions of polymer/green-synthesized graphene nanocomposites and their utility in supercapacitor components. Green graphene-derived nanocomposites brought about numerous revolutions in high-performance supercapacitors. The structural diversity of conjugated polymer and green graphene-based nanocomposites has facilitated the charge transportation/storage capacity, specific capacitance, capacitance retention, cyclability, and durability of supercapacitor electrodes. Moreover, the green method, graphene functionality, dispersion, and matrix–nanofiller interactions have affected supercapacitance properties and performance. Future research on innovative polymer and green graphene-derived nanocomposites may overcome design/performance-related challenging factors for technical usages.

A flexible filter paper based composite electrode was prepared via the convenient one-step synthesis of silver doped graphene for the first time, followed by in-situ polymerization of aniline monomers. Using L-ascorbic acid for simultaneous reduction of grapheme oxide and silver nitrate, we provided a new and green method to prepare graphene hybrid sheets without toxicity. It was found that the as-fabricated hybrid electrode formed a three-dimensional porous architecture, which not only increased the specific surface area of composite, but also facilitated the ion diffusion of the electrolyte. In addition, according to the tests of electrochemical performances, the flexible hybrid electrode subsequently exhibited exceptional specific capacitance of 437.3 F/g, energy density of 1133.5 W·h/kg and power density of 88.8 kW/kg, respectively. Meanwhile, the as-prepared hybrid demonstrated a good cycling stability with only 10.99% specific capacitance deterioration after 5000 times of cycling. This preparation technology presented here shows great potential for the development and application of wearable and portable energy storage devices, particularly for flexible supercapacitors. Moreover, this study puts forward a general, simple and low-cost route of fabricating a novel flexible electrode on a large scale, eventually for environmental protection.

An asymmetric supercapacitor was prepared on a sheet of filter paper with two modified surfaces acting as electrodes in 1 M potassium hydroxide aqueous solution. By choosing carbon nanotubes and two different kinds of metal oxides (zinc oxide and ferro ferric oxide) as electrode materials, the asymmetric supercapacitor was successfully fabricated. The results showed that this device exhibited a wide potential window of 1.8 V and significantly improved electrochemical performances of its counterparts. Particularly, the one-sheet asymmetric supercapacitor demonstrated high energy density of 116.11 W h/kg and power density 27.48 kW/kg, which was attributed to the combined action and shortened distance between the two electrodes, respectively. Besides, it showed superior electrochemical cycling stability with 87.1% capacitance retention under room temperature. These outstanding results can not only give researchers new insights into compact energy storage systems, but they also provide a good prospect for flexible asymmetric supercapacitors.

The thermally conductive properties of silicone thermal grease enhanced by hexagonal boron nitride (hBN) nanosheets as a filler are relevant to the field of lightweight polymer-based thermal interface materials. However, the enhancements are restricted by the amount of hBN nanosheets added, owing to a dramatic increase in the viscosity of silicone thermal grease. To this end, a rational structural design of the filler is needed to ensure the viable development of the composite material. Using reduced graphene oxide (RGO) as substrate, three-dimensional (3D) heterostructured reduced graphene oxide-hexagonal boron nitride (RGO-hBN)-stacking material was constructed by self-assembly of hBN nanosheets on the surface of RGO with the assistance of binder for silicone thermal grease. Compared with hBN nanosheets, 3D RGO-hBN more effectively improves the thermally conductive properties of silicone thermal grease, which is attributed to the introduction of graphene and its phonon-matching structural characteristics. RGO-hBN/silicone thermal grease with lower viscosity exhibits higher thermal conductivity, lower thermal resistance and better thermal management capability than those of hBN/silicone thermal grease at the same filler content. It is feasible to develop polymer-based thermal interface materials with good thermal transport performance for heat removal of modern electronics utilising graphene-supported hBN as the filler at low loading levels.

A novel high-performance carbon foam (CF) was fabricated through the addition of phenolic resin (PR) into a coal tar pitch (CTP) based precursor. The effects of mass fraction of a PR additive on the crystalline structures, morphologies, compressive strength (σ) and thermal conductivity (λ) of resultant CF material were investigated systematically. Characterization showed a strong dependence of CF’s performance from the composition and optical texture of the precursor, which were mainly depending on the polycondensation and polymerization reactions between PR and raw CTP. Comparing with the strength of pristine CF at 6.5 MPa, the σ of mCF-9 (13.1 MPa) was remarkably enhanced by 100.1%. However, the λ of mCF-9 substantially reduced to 0.9 m−1K−1 compared with 18.2 W m−1K−1 of pristine CF. Thus, this modification strategy to produce microporous CF materials from raw CTP provides a new protocol for the fabrication of high-performance carbon based materials.

With developments of the electronics industry, more components are being included in electronic devices, which has led to challenges in thermal management. Using reduced graphene oxide embedded with MQ silicone resin (RGO/MQ) nano-aggregates as the composite filler and silicone rubber (SR) as the matrix, a simple approach is designed to prepare RGO/MQ/SR composites. Reduced graphene oxide (RGO) was first used as a substrate for the growth of MQ silicone resin by hybridization, forming sandwich-like micro structured RGO/MQ nano-aggregates successfully. Then, RGO/MQ was integrated into α,ω-dihydroxylpolydimethylsiloxane based on the in situ solvent-free blending method, followed by condensation and vulcanization, fabricating the final RGO/MQ/SR composites. The effective strategy could enhance the adaptability between graphene and silicone matrix under external stimuli at room temperature by embedding nanoscale MQ into the interface of graphene/silicone as the buffer layer. Obvious improvements were found in both thermal conductivity and mechanical properties due to excellent dispersion and interfacial compatibility of RGO/MQ in the host materials. These attractive results suggest that this RGO/MQ/SR composite has potential as a thermal interface material for heat dissipation applications.

The synthesis of 3D lamellar graphene/BaFe12O19 composites was performed by oxidizing graphite and sequentially self‐propagating combustion triggered process. The 3D lamellar graphene structures were formed due to the synergistic effect of the tremendous heat induced gasification as well as huge volume expansion. The 3D lamellar graphene/BaFe12O19 composites bearing 30 wt % graphene present the reflection loss peak at −27.23 dB as well as the frequency bandwidth at 2.28 GHz (< −10 dB). The 3D lamellar graphene structures could consume the incident waves through multiple Reflection and scattering within the layered structures, Prolonging the propagation path of electromagnetic waves in the absorbers.