Advanced ternary carbon-based hybrid nanocomposites for electromagnetic functional behavior in additive manufacturing

• Published in: Applied materials today 2024-10, Vol.40, p.102362, Article 102362
• Main Authors: Ribeiro dos Anjos, Erick Gabriel, Passador, Fabio Roberto, de Carvalho, André Balogh, Rezende, Mirabel Cerqueira, Sundararaj, Uttandaraman, Pessan, Luiz Antonio
• Format: Article
• Language: English
• Subjects: Additive manufacturing; Carbon nanofillers; Electromagnetic compatibility; Ternary hybrid nanocomposites
• ISSN: 2352-9407
• DOI: 10.1016/j.apmt.2024.102362

•New ABS-based ternary hybrid (carbon nanotubes/graphene nanoplatelets/carbon black) nanocomposites with superior electric and electromagnetic performance were developed.•A concise and complete comparison of how different industrial-like process strategies result in different overall performances for nanocomposites.•Additive manufactured samples of ABS-based ternary hybrids nanocomposites have achieved up to 42 dB of SET at 11.8 GHz. This study explores the processing and performance of acrylonitrile butadiene styrene (ABS)-based carbon ternary hybrid nanocomposites, incorporating carbon nanotubes (CNT), graphene nanoplatelets (GNP), and carbon black (CB), for applications in electromagnetic compatibility (EMC). The effect of nanocomposite processing on electromagnetic properties was evaluated by varying the mixing protocol, either through direct extrusion with simultaneous addition of all constituents or by preparing a master batch followed by dilution. The impact of nanofiller morphology and processing techniques on the behavior of nanocomposites was systematically investigated. Filaments of these nanocomposites were Additive Manufactured via Material Extrusion, and the resulting parts were evaluated for EMI shielding effectiveness (SE) in the X-band frequency range. The study reveals that the morphology, influenced by the processing strategy, significantly impacts the EMI SE properties of the printed samples. Particularly, ternary hybrids 3/3/3 wt% (CNT/GNP/CB) nanocomposites demonstrate promising electrical (0.003 S/cm), electromagnetic (29 dB of total attenuation), and mechanical performance (elastic modulus of 3080 MPa), with a clear advantage observed in those processed via direct extrusion. These nanocomposites were validated as feedstock filaments for 3D printing, and the printed sample exceeds the injection molded behavior for the composition 3/3/3 wt% (CNT/GNP/CB), achieving 40 dB of total attenuation at 11.8 GHz. The findings contribute valuable knowledge into tailoring nanocomposite formulations for additive manufacturing applications in EMI shielding, providing a nuanced understanding of the interplay between processing strategies, nanocomposite morphology, and resulting material properties. [Display omitted]