Carbon-fibre reinforced composites are seeing increased deployment, especially in the aerospace industry, and the next-generation of these materials will need to meet demanding performance requirements beyond just specific strength. The incorporation of nanomaterials such as graphene into composites has great potential for enhancing electrical, thermal, and mechanical properties, which could then enable new capabilities such as built-in lightning strike protection and electromagnetic shielding. One major challenge is successful integration of nanomaterials into the composite during the manufacturing process especially for thermoplastic based composites. This work explores the spray deposition of exfoliated graphene in liquid suspensions for the nano-enhancement of electrical properties in carbon-fibre reinforced polyether ether keytone (PEEK) composites. Developed thin films were smooth with RMS roughness of 1.06 μm on Si substrates and RMS roughness of 1.27 μm on CF-PEEK tapes. The addition of 1.3 wt% graphene into the interlayers of CF-PEEK composites resulted in bulk electrical conductivity enhancement both in plane and through thickness of ~ 1100% and 67.5% respectively. This approach allows for pre-consolidation introduction of high-performance nanomaterials directly to thermoplastic prepregs which could open simple pathways for the in-situ manufacturing of carbon-fibre reinforced polymer nanocomposites.
Graphene enhanced thermoplastic composites offer the possibility of conductive aerospace structures suitable for applications from electrostatic dissipation, to lightning strike protection and heat dissipation. Spray deposition of liquid phase exfoliated (LPE) aqueous graphene suspensions are highly scalable rapid manufacturing methods suitable to automated manufacturing processes. The effects of residual surfactant and water from LPE on thin films for interlaminar prepreg composite enhancement remain unknown. This work investigates the effect of heat treatment on graphene thin films spray deposited onto carbon fibre/polyether ether ketone (CF/PEEK) composites for reduced void content. Graphene thin films deposited onto CF/PEEK prepreg tapes had an RMS roughness of 1.99 μm and an average contact angle of 11°. After heat treatment the roughness increased to 2.52 μm with an average contact angle of 82°. The SEM images, contact angle, and surface roughness measurements correlated suggesting successful removal of excess surfactant and moisture with heat treatment. Raman spectroscopy was used to characterise the chemical quality of the consolidated graphene interlayer. Spectral data concluded the graphene was 3–4 layered with predominantly edge defects suggesting high quality graphene suitable for electrical enhancement. Conductive-AFM measurements observed an increase in conductive network density in the interlaminar region after the removal of surfactant from the thin film. Heat treatment of the Control sample successfully reduced void content from 4.2 vol% to 0.4 vol%, resulting in a 149% increase in compressive shear strength. Comparatively, heat treatment of graphene enhanced samples (~ 1 wt%) reduced void content from 5.1 vol% to 2.8 vol%. Although a 25% reduction in shear strength was measured, the improved electrical conductivity of the interlaminar region extends the potential applications of fibre reinforced thermoplastic composites. The heat treatment process proves effective in reducing surfactant and thus void content while improving electrical conductivity of the interlayer in a scalable manner. Further investigations into graphene loading effects on conductive enhancement, and void formation is needed.
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