Efficient fabrication of high-quality graphene via alternating-current co-intercalation and microwave-assisted expansion

Abstract

To facilitate the transformation of inexpensive and abundant graphite resources into two-dimensional graphene materials with promising applications, the development of efficient, cost-effective, and scalable technologies for large-scale production of high-quality graphene is crucial. Here, we propose an effective electrochemical dual-electrode co-intercalation exfoliation strategy. During the process, precise control of the electrochemical intercalation is achieved by adjusting the working bias and alternating current (AC) cycle, while ensuring the ion insertion rate through gradual voltage escalation. Repeated insertion of cations and anions under AC accelerates the graphite exfoliation. Following complete ion inserting, suitable microwave processing was employed to achieve rapid graphite expansion. Ultimately, ultra-sonication in NMP is employed to achieve final exfoliation between graphite layers. The resulting few-layer graphene (2–3 layers) exhibited minimal defects (ID/IG = 0.0405), low oxygen content (C/O = 44.62), high yield (95.3 %), and excellent conductivity (625 S/cm), enabling its potential commercialization and large-scale application. This outcome also serves as a significant reference for the commercial production of environmentally friendly and cost-effective graphene.