Session: 04-26-01: Nanoengineered, Nano Modified, Hierarchical, Multi-Scale Materials and Structures

Paper Number: 166669

Cryogenic Milling of Soft Graphite Powder Into Graphene Nanoflakes for Improved Corrosion Resistance of Copper Plates 

Graphene, a recently discovered allotrope of carbon composed of a single layer of carbon atoms arranged in a two-dimensional (2D) hexagonal lattice, exhibits extraordinary mechanical, electrical, and chemical properties. It is approximately 200 times stronger than steel while remaining lighter than paper, making it an attractive material for various applications, including electronics, energy storage, composites, and protective coatings. Among its many potential applications, the use of graphene-based materials in corrosion protection has gained significant interest due to their exceptional barrier properties and resistance to chemical degradation. Protecting metal surfaces from corrosion and environmental degradation is a critical concern across multiple industries, particularly in marine, aerospace, and infrastructure sectors. Various methods, including anodization, electrochemical plating, and inhibitor treatments, have been employed for corrosion protection, but coating remains the most widely adopted method due to its cost-effectiveness, ease of application, and efficiency in preventing direct exposure of metals to corrosive environments.

Graphene-based coatings offer a promising alternative to conventional corrosion-resistant coatings due to their impermeability to gases and liquids, chemical inertness, and excellent mechanical properties. Despite graphene’s high intrinsic strength, its reinforcing effect in coatings is often limited due to challenges in dispersion, adhesion, and layer stacking. In this study, homegrown graphene was synthesized using a cryogenic milling approach, where soft graphite was mechanically processed at extremely low temperatures to produce fine graphene and graphite particles. These graphene-based materials were then incorporated into a polymeric coating matrix at varying weight percentages and applied to copper plates as a protective layer. The coated specimens were subjected to a standardized 30-day salt bath immersion test to evaluate their corrosion resistance under harsh conditions. The experimental results revealed that even a modest incorporation of graphene or finely milled graphite significantly improved the corrosion resistance of the coated copper surfaces. The enhanced performance was attributed to the graphene's ability to form a highly impermeable and dense protective barrier, reducing the penetration of corrosive agents such as chloride ions and moisture.

The findings from this research highlight the potential of graphene as an effective additive in protective coatings for enhancing the durability and lifespan of metallic structures in corrosive environments. Future studies may focus on optimizing graphene dispersion techniques and exploring hybrid graphene-based coatings to further enhance performance. The use of graphene in protective coatings presents a viable, sustainable, and technologically advanced approach to corrosion mitigation, with promising implications for industrial and commercial applications. Additionally, the scalability of graphene production and its integration into large-scale coating processes could pave the way for widespread adoption in diverse engineering applications.

 

 

 

 

 

 

 

 

 

Presenting Author: Ramazan Asmatulu Wichita State University, 1845 Fairmount St., Wichita, KS, USA

Presenting Author Biography: Dr. Ramazan Asmatulu is a Full Professor in the Department of Mechanical Engineering at Wichita State University in the USA. His current research mainly focuses on the synthesis, characterization, and mechanical properties of various nanomaterials, nanocomposites, and biomaterials for primarily aerospace, energy, environment, and biomedical applications.

Authors:

Punit Singh Wichita State University, Department of Mechanical Engineering
Waseem Khan University of Wisconsin-Platteville, 174 Sesquicentennial Hall , 1 University Plaza Platteville, WI 53818
Muhammad Rahman Air Force Institute of Technology, Wright Patterson AFB, OH, USA
Ramazan Asmatulu Wichita State University, 1845 Fairmount St., Wichita, KS, USA