Abstract
Despite their excellent mechanical performance, carbon fiber-reinforced polymer (CFRP) composites are limited by the interfacial properties due to the inherent nature of laminated structures. One way to modify the interface is by the inclusion of nanomaterials. Here, we use electrochemical exfoliation to produce graphene (EEG) flakes that have hydroxyl and epoxy functional groups. To further improve the interfacial bonding, silanization was carried out on graphene with 3-aminopropyl triethoxysilane, and then, EEA flakes were achieved. Both flakes were dispersed in ethanol and spray-coated onto carbon fibers, followed by vacuum-assisted resin infusion to make hybrid composites. Testing of their mechanical properties showed that EEG flakes tend to act as points of stress concentration, which accelerated the delamination, while the EEA flakes improved interfacial properties owing to the covalent bonding. As a result, with only 0.5 wt % EEA flakes spray-coated onto the carbon fibers, the tensile and flexural strength of graphene/carbon fiber composites improved by 17.6 and 5.4%, respectively. The combination of electrochemical exfoliation, silanization, spray coating, and vacuum-assisted resin infusion enables large-scale hybrid composite fabrication without size or shape limitations, without weakening the CFs or carbon fabric patterns, and is suitable for continuous production. This process has proven to be practical and attractive for engineering applications.