Due to their outstanding specific mechanical and functional properties, the engineering use of polymer nanocomposites and their carbon composites is becoming increasingly pervasive. Current and potential applications include micro- and flexible electronics, energy storage devices, and the use as reinforcement for advanced carbon fiber composites for light-weighting of aerospace and mechanical structures, thereby reducing their fuel consumption and carbon footprint. While a large amount of data and models regarding the effect of the weight fraction of nanoplatelets on the mechanical properties of nanocomposites is currently available in the literature, an aspect often overlooked is the scaling of the fracture behavior and the related particle size effects. Not only is the lack of understanding of size effects in nanomaterials hindering the full exploitation of their properties, it is also a serious issue since the design of large nanocomposite structures or small-scale electronic components requires capturing the scaling of their mechanical properties and developing predictive capabilities. This paper aims at filling this knowledge gap by proposing a novel analytical and experimental approach to investigate particle size effects in nanocomposites at and leveraging the acquired knowledge to improve their fracture properties, from the nanoscale all the way to the macroscale. To this end, crack initiation fracture toughness data for graphene/epoxy nanocomposite are presented as a function of nanoparticle size and weight fraction and compared with model predictions using a novel analytical model based on enhanced crack-tip shielding effect due to the reduced nanoparticle size. Extensive fracture test data are presented for model calibration and model verification.
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