Electrochemically exfoliated graphene-like nanosheets for use in ceramic nanocomposites

In this work, the synthesis of graphene-like nanosheets (GNS) by an electrochemical exfoliation method, their microstructural characterization and their performance as fillers in a ceramic matrix composite have been assessed. To fabricate the composites, 3 mol % yttria tetragonal zirconia (3YTZP) powders with 1 vol % GNS were processed by planetary ball milling in tert-butanol to enhance the GNS distribution throughout the matrix, and densified by spark plasma sintering (SPS). According to a thorough Raman analysis and SEM observations, the electrochemically exfoliated GNS possessed less than 10 graphene layers and a lateral size lower than 1 μm. However, they contained amorphous carbon and vacancy-like defects. In contrast the GNS in the sintered composite exhibited enhanced quality with a lower number of defects, and they were wavy, semi-transparent and with very low thickness. The obtained nanocomposite was fully dense with a homogeneous distribution of GNS into the matrix. The Vickers hardness of the nanocomposite showed similar values to those of a monolithic 3YTZP ceramic sintered in the same conditions, and to the reported ones for a 3YTZP composite with the same content of commercial graphene nanosheets.