Why is Graphene added to composite materials?

Composites are at the heart of material innovation. Engineers have experimented with novel material mixtures since prehistory, concrete being the prime example. This rudimentary mixing of earthen materials still has a role to play in modern society. However, the science of composite manufacturing now occupies the forefront of materials science, notably, in the application of graphene additives.

Graphene promised revolutionary applications across various fields when it was first isolated in 2004. Comprising a single layer of carbon atoms arranged in a two-dimensional honeycomb lattice, the world’s first truly 2D material demonstrated exceptional strength, electrical conductivity, and flexibility. But manufacturers struggled to deliver on that promise. 

The problem of this material’s commercialisation has been well-reported but can be summarised as an issue of scalability. Conversely, composite manufacturing is a comparative success story for graphene development. 

Integrating graphene powders as an additive to existing materials conferred many of its benefits to the real world. Researchers believe that graphene composite materials could be the first true breakthrough application of the material that previously promised so much over the last two decades.

A quick primer on composites

Graphene composite materials are made by incorporating graphene into host materials. This can improve the material’s underlying properties, such as their tensile strength. These host materials include:

  • Polymers
  • Metals
  • Ceramics

These characteristics are also dependent on the surface area of the graphene composite materials. 

The nature of the inclusion process varies based on the host material, manufacturing pipeline, and end-use scenario. However, a few common ways that graphene powders are introduced into a composite matrix include:

  • Mechanical mixing: This method involves the direct mixing of graphene with the matrix material through mechanical stirring or ultrasonication. The challenge here is to achieve a uniform dispersion of graphene within the matrix. That way the effective transfer of its properties to the composite can be assured.
  • In situ polymerization: In this method, graphene is dispersed within a monomer solution before polymerization. The presence of this material can act as a nucleation site for polymerization. It can lead to a composite where graphene is well dispersed within the polymer matrix. 
  • Solution blending: This involves dissolving both graphene and the polymer in a common solvent. This is followed by the removal of the solvent, leaving behind a composite material.
  • Melt blending: Melt blending is used primarily with thermoplastic polymers. This is where both the polymer and graphene are heated until the polymer melts, and then they are combined together. 

This method is advantageous for its simplicity and for not requiring solvents. But it does involve careful control of the temperature to avoid degrading the polymer or damaging the graphene.

These integration methods highlight the wider adoption of graphene in the composites industry and suggest significant market growth. Indeed, the market was valued at $13.1 million in 2019 and is estimated to reach $109.4 million by 2027. This growth trajectory highlights the increasing demand for advanced materials in various industrial sectors. It could also potentially demonstrate a second-wind of interest in graphene materials.

Applications of graphene composite materials

Automotive

In the automotive sector, this material is utilized to enhance fibre-reinforced polymer composites, reducing weight and improving mechanical resilience. For instance, collaborating with the Briggs Automotive Company on the Mono R resulted in a 22% weight reduction in bodywork by incorporating functionalised graphene. This weight reduction is crucial for lightweight vehicles, like the Mono R. Moreover, graphene-enhanced tooling epoxy resin is used to manufacture carbon fibre tools efficiently.

Aerospace

Success stories in the graphene composites sector underscore the material’s potential to revolutionize industries. For example, we, Haydale, have collaborated with notable firms like Airbus UK and BAE Systems. This was to develop enhanced materials for aerospace, offering improved electrical conductivity and mechanical properties​​.

Sporting goods

Our partnership with the University of Manchester’s Graphene Engineering Innovation Centre (GEIC) has renewed for a sixth year. This partnership has led to significant advancements, including the development of products like:

  • Carbon composite body panels for sports cars 
  • Novel coating processes. 

Together, we are committed to furthering the adoption of advanced materials to address global challenges. Our focuses are on providing premium products that add substantial value to various industries.

Long-lasting tools

Functionalised graphene can be added to high-performing tooling epoxy resin for the manufacturing of automotive tools. This application aims to address the need for lightweight materials in vehicles by using graphene-enhanced fiber-reinforced polymer composites. We have worked with companies like Briggs Automotive Company (BAC) to reduce bodywork weight by 22% using graphene-enhanced materials.

Interested in graphene composite materials?

Functionalised graphene has been chemically modified to enhance its properties for various applications. It is developed by a number of companies worldwide using various methods. 

Here at Haydale, we use a proprietary plasma functionalisation process called HDPlas©. This allows for the effective dispersion of graphene into different media like water, inks, and elastomers. The process enhances the properties of graphene, offering benefits such as improved mechanical strength, increased electrical and thermal conductivity, and environmental friendliness. 

If you are interested in learning more, our team would be happy to answer any queries.