Cu-Expanded Graphite Composite Material Preparation and Thermal Properties

Tribological Properties of Nitrate Graphite Foils

This study investigates the tribological properties of graphite foils (GF) with densities of 1.0, 1.3, and 1.6 g/cm3, produced from purified natural graphite of different particle sizes (40-80 μm, 160-200 μm, >500 μm). Surface roughness was measured after cold rolling and friction testing at static (0.001 mm/s) and dynamic conditions (0.1 Hz and 1 Hz). Results showed that static friction tests yielded similar roughness values (Sa ≈ 0.5-0.7 μm, Sq ≈ 0.5-1.0 μm) across all densities and particle sizes. Dynamic friction tests revealed increased roughness (Sa from 0.7 to 3.5 μm, Sq from 1.0 to 6.0-7.0 μm). Friction coefficients (µ) decreased with higher sliding speeds, ranging from 0.22 to 0.13. GF with 40-80 μm particles had the lowest friction coefficient (µ = 0.13-0.15), while 160-200 μm particles had the highest (µ = 0.15-0.22). Density changes had minimal impact on friction for the 40-80 μm fraction but reduced friction for the 160-200 μm fraction. Young's modulus increased with density and decreased with particle size, showing values from 127-274 MPa for 40-80 μm, 104-212 MPa for 160-200 μm, and 82-184 MPa for >500 μm. The stress-strain state in the graphite foil samples was simulated under normal and tangential loads. This makes it possible to investigate the effect of the anisotropy of the material on the stress concentration inside the sample, as well as to estimate the elasticity modulus under normal compression. Structural analyses indicated greater plastic deformation in GF with 40-80 μm particles, reducing coherent-scattering region size from 28 nm to 24 nm. GF samples from 160-200 μm and >500 μm fractions showed similar changes, expanding with density increase from 18 nm to 22 nm. Misorientation angles of GF nanocrystallites decreased from 30° to 27° along the rolling direction (RD). The coherent scattering regions of GF with 40-80 μm particles increased, but no significant changes in the coherent scattering regions were observed for the 160-200 μm and >500 μm fractions during dynamic friction tests. Microstrains and residual macrostresses in GF increased with density for all fractions, expanding under higher friction-induced loads. Higher values of both stresses indicate a higher level of accumulated deformation, which appears to be an additional factor affecting the samples during friction testing. This is reflected in the correlation of the results with the roughness and friction coefficient data of the tested samples.

Anisotropy of Electrical and Thermal Conductivity in High-Density Graphite Foils

Flexible graphite foils with varying thicknesses (S = 282 ± 5 μm, M = 494 ± 7 μm, L = 746 ± 8 μm) and an initial density of 0.70 g/cm3 were obtained using the nitrate method. The specific electrical and thermal conductivity of these foils were investigated. As the density increased from 0.70 g/cm3 to 1.75 g/cm3, the specific electrical conductivity increased from 69 to 192 kS/m and the thermal conductivity increased from 109 to 326 W/(m·K) due to the rolling of graphite foils. The study showed that conductivity and anisotropy depend on the shape, orientation, and contact area of thermally expanded graphite (TEG) mesoparticles (mesostructural factor), and the crystal structure of nanocrystallites (nanostructural factor). A proposed mesostructural model explained these increases, with denser foils showing elongated, narrowed TEG particles and larger contact areas, confirmed by electron microscopy results. For graphite foils 200 and 750 μm thick, increased density led to a larger coherent scattering region, likely due to the rotation of graphite mesoparticles under mechanical action, while thinner foils (<200 μm) with densities > 1.7 g/cm3 showed increased plastic deformation, indicated by a sharp reduction in the coherent scattering region size. This was also evident from the decrease in misorientation angles with increasing density. Rolling reduced nanocrystallite misorientation angles along the rolling direction compared to the transverse direction (TD) (for 1.75 g/cm3 density ΔMA = 1.2° (S), 2.6° (M), and 2.4° (L)), explaining the observed anisotropy in the electrical and mechanical properties of the rolled graphite foils. X-ray analysis confirmed the preferred nanocrystallite orientation and anisotropy coefficients (A) using Kearns parameters, which aligned well with experimental measurements (for L series foils calculated as: A0.70 = 1.05, A1.30 = 1.10, and A1.75 = 1.16). These calculated values corresponded well with the experimental measurements of specific electrical conductivity, where the anisotropy coefficient changed from 1.00 to 1.16 and mechanical properties varied from 0.98 to 1.13.