Robust natural graphite-based bulk graphites with nanodiamond-containing fibrous nanofiller as reinforcement by electrohydrodynamic processing

Abstract

One-dimensional (1D) structures, such as carbon nanotubes and carbon fibers, used as reinforcements in advanced carbon materials, have been greatly appreciated but facing with some significant challenges of dispersion and interfacial bonding. We utilized electrospinning technology to create a new 1D nanofiller. This material is a superfine fiber composed of polyacrylonitrile (PAN) with a high nanodiamond (ND) content of 75 %, which is referred to as PDNF. During the preparation process, these nanofillers were blended with natural flake graphite (NFG) through electro-spraying. The as-prepared mixture served as the precursor powder sintered into NFG-based high-strength bulk graphite (HPG). During spark plasma sintering at 1800 °C, fibrous PDNF undergoes a phase transformation of diamond to graphite, with onion carbon pinning into and markedly reducing cleavage along the (002) plane of NFG, foundational to the high strength of NFG-based HPG. The PDNF's fiber-like structure and NFG's flake structure greatly increase the interfacial area between the matrix and reinforcement. Furthermore, the PDNF excels at blunting and deflecting cracks, thus bolstering the NFG-based HPG's overall resistance to crack propagation. The density, Young's modulus, and flexural strength of the as-prepared NFG-based HPG achieve 1.65 g/cm3, 17.4 GPa, and 145 MPa, respectively. Most importantly, this process can be a general approach for other high-performance composite materials.