fabrication and machining aspects in ngrp composite …

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 14, Number 2, 2019 (Special Issue) © Research India Publications. http://www.ripublication.com

Fabrication and Machining aspects in NGRP Composite Materials

Vikas Kumar

Mechanical Engineering Department

Madan Mohan Malaviya University of

Technology

Gorakhpur 273010, India.

Prakhar Kumar Kharwar Mechanical Engineering Department


Technology


Dr. Rajesh Kumar Verma Mechanical Engineering Department


Technology


Abstract— The Natural Graphite Reinforced Polymer

(NGRP) composites is extensively used in the aerospace

industry, locomotive and electronic insulator due to its

engineering properties such as High thermal conductivity,

strength to weight proportion. Hand lay-up method is used to

make graphite-based polymer composite. The main intention to

produce the multi-phase polymer matrix when combining the

polymer resin and filler is to increase to the asset of polymer

compound. XRD, FE-SEM & HR-SEM has been used to find

out the building as well as morphology of prolonged graphite

compound. Basically there are four types of modification of

graphite namely graphene oxide, graphite intercalation

compound, expanded graphite & graphene. The intention of

increasing the percentage of expanded graphite is due to the

enhanced thermal stability of epoxy. The graphite nanoparticle

is majorly used because it increases the mechanical, thermal,

electrical effect during the fabrication of composite polymer. In

this paper an attempt has been made to identify the various

mechanical properties, fabrication and machining aspects of

NGRP composites and previous research done by the pioneer

researchers.

Keywords— Natural graphite, Epoxy, Extended graphite,

Nano- particle graphite.

I. INTRODUCTION

Now-a-days, fiber-strengthened polymer mixtures are used

in areas of manufacturing and aerospace application as well

as in locomotive quantities and microelectronic insulator.

So, fiber strengthened polymer synthesis need a specific in

height for execution [1-4]. Fiber strengthened polymer

mixtures are identified through strong ability weak definite

heaviness, high biochemical confrontation alongside erosion

[5-7]. A polymer resin presently needed in matrix material

for fiber reinforced composites is epoxy resins; the reason

being they have outstanding mechanical possessions, scrape

fighting and organic confrontation and also broadly

requiring a different use like glues, coverings, as well as in

shields [8-10]. Normal graphite chips are found in plenty in

environment as well have low cost, easily deform in two

dimensional constituents through great power, great

modulus standards, small deformability on high

temperature, small thermal growth coefficient, in addition to

great aspect ratio [11-16].

So, NGFs show great thermal conductivity, outstanding

thermal shockwave in addition to great rupture durability.

Graphite is in the form of natural flake to consume merit

towards linkage of interface using polymer matrix taking

place to the fabrications of compounds.

Graphite in the form of flakes has been distributed in a

solution of resin as it advances the mechanical properties of

interface of the specimen to strand strengthened mixtures.

Natural graphite flake was attractive material in areas of

great temperature application [17-20].

A three period of natural graphite strip/basal fiber/epoxy

mixtures were made since combination of basal fiber with

natural-strengthened epoxy gums can produce a broader

synergetic consequence happening on the warm air and

powered merits.

The composite made with naturally available graphite has

better design aspect as well as provides improved

mechanical power and thermal possessions at very small

expense.

To find out the direct connection to the thermal conductivity

as well as with crack stiffness through the external energy of

the compounds results into the synergetic influence of the

naturally obtained graphite.

II. PRODUCTION OF NATURAL GRAPHITE FLAKES/BASAL

FIBRES/EPOXY COMPOSITE

Fig.1. shows the fabrication process of NGFs/BFs/Epoxy

composite. NGFs/BFs/Epoxy composite has been used for

manufacturing by taking 70g epoxy resin along with the

naturally obtained graphite substance by varying weight

percentage at 10%, 20%, 30% & 40%. The epoxy resin has

been stabilized at 60˚C for 30minutes.

Fig. 1. Arrangements of Natural graphite strip/Basal fiber/Epoxy

compounds [21]

After the resin and natural graphite has been stirred in the

form of planetary combination intended used for three

minute and also the bubble has been escaped to an

emptiness furnace used for one hour.

Hand-lay-up method is used for the impregnated 35g of BFs

with epoxy and NGF. The laminated plate is hot pressed

(3MPa, 170˚c, 200min), which makes the final specimen

hard. The specimens have been named as NGB10, NGB20,

NGB30, NGB40, simultaneously.

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A. Effect of surface properties and interfacial effects of the

composite

The NGFs and matrix, composite surface is measured with a

RAME-Hart goniometer. Those value are calculated to

establish the interaction position among the watery and

compact to the recognized superficial free energy standards

and to gain detail along with exact surface energy evidence

designed for the compounds. Essential calculation designed

for thermal conductivity

k= (1)

Model of the thermal conductivity is denoted by k,

thermally diffuse of model has been represented with α

whereas ρ shows the concentration of the material with the

specific heat of the material being Cp. The specific heat has

been determined by DSC and the density has been measured

through densimetre and the diffusivity of material is

obtained by the Equation:

(2)

Where “L” is the wideness of the sample and “t” being the

time [22]. The conductivity of sample has thermally been

influenced through the graphite flakes assembled inside the

medium, along with the packing, thermal confrontation has

also been distributed on the boundary among the natural

graphite and resin medium. The thermal conductivity values

have been increased along with growing natural graphite

flake substance. It has stated that capable transmission

systems have systematically been influenced via natural

graphite substance because of great feature-relation natural

graphite elements make a thermal of pathway [23-25].

Therefore, natural graphite flake is used as putties donated

to the composites which is thermally conductive in nature

for the reason that of tremendous thermal possessions of

composite.

The updraft steadiness of natural graphite/basal fiber/epoxy

resin combinations is better by growing natural graphite

substance. Composite materials which are thermally

decomposed are extra tough owing to the warmth

confrontation of the natural graphite. The mechanical

interfacial goods of the natural graphite /basal fiber /epoxy

compounds rendering to the substance of natural graphite is

study by splintering robustness dimensions to survey crash

progress confrontation. Rupture hardness has powerfully

connected interfacial powers among stuffing and medium.

[25, 22, 27].

Calculations for Critical stress intensity factor ( ) has

computed after that calculation used for rupture strength

limit through critical strain energy release rate [53-56]:

Where,

Y= (3)

(4)

III. CHARACTERISATION REVIEW OF COMPOSITE POLYMER

A composite has a phenomenon to show the thermal

conductivity and also it is used to measure extra than three

intervals taking a thermally conductivity analyzer (LFA 447

Nano Flash® Nederland, Germany). The size of the sample

is 2mm×10 mm×10 mm and is layered through spray. An

ultraviolet updraft camera is used to portion of the heat

absorption ability to the produce sample.

New temperature limit has stabilized on 30°C aimed at 30

minutes under the atmosphere of nitrogen also the decline of

weight by means of growing temperature has been analyzed

during sustaining of heating system rate at 10 °C per minute.

Conferring to a three-point bending check used to identify

the rupture durability of compound through a universal

tensile machine tester (Lloyd LR5k) of critical stress

intensity factor associated with American standard of testing

machine (ASTM E399). The size of the model is in the

limits of 5mm×10 mm×50mm and the notch depth is partial

to the thickness and also the crosshead quickness is about 10

mm/min. A rupture flat of testing compounds is platinum-

covered also the great-determination of look over to the

electron microscope is used to detect the profile of the

rupture flat. (a)

(b) Fig.2. shows the graph of natural graphite/basal fiber/epoxy

compounds such as a utility of natural graphite substance:

(a) graph of sample which are thermally conductive in

nature (b) Change of temperature distribution related to the

time [28]

The RAME-Hart goniometer (Phoenix 300 Plus, SEO Co.)

of sessile drop technique is used to detect the angle of

contact. There are basically three ways of soaking water to

execute dimensions; purified liquid, diode methane &

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ethylene glycol. The volume of droplet to all regular soaking

water has been determined up to 5 micro-liters.

IV. IMPROVE THE PROPERTIES OF COMPOSITE USING

EXTENDED GRAPHITE AS A FILLER

A solution of mixing method is used to make the reinforced

for epoxy composite of expanded graphite. Polymer resin

and filler are combined to increase the assets of matrix

compound and produce multi-phase polymer matrix

composite. We can say that different type of filler is used to

advance the physical possessions of compounds. In the

region of composite, the field emission electron Microscopy

(FE-SEM), high resolution transmission of electron

microscopy (HR-TEM) and also X-ray diffraction (XRD) is

used to find out the building as well as morphology of

prolonged graphite/epoxy compound. Various studies are

done on conducting filler like carbon nanotube and graphite

is the main reason to improve their skill towards progress of

the thermal, electrical and mechanical possessions to natural

polymer. Conductive polymer is either essentially

conductive in nature or protecting polymer compound

through the conductive filler. Composites are applied in

bright producing equipment, sets, electromagnetic protecting

and additional application [29-31]. Conductive stuffing for

example carbon black, carbon nanotube and natural graphite

is efficiently find out. This type of filler is applied to

efficiently advance the electrical conductivity of the

polymers. When we find out relation among the carbon

nanotube, graphite continues to evoke significant

observation for the reason that of their mechanical and

electrical belongings, little compactness, informal

dispensation also small price [32-37].

Chen et al. [38] measured the stretchable power of the

expanded graphite/polystyrene compound and also found its

stretchy power which were slightly advanced compared to

the unadulterated polystyrene.

Kim et al. [39] equated to the updraft possessions of unused

polylactic acid through the expanded graphite compounds

also establish the updraft constancy for the developments

rise through the substance of expanded graphite.

The updraft possessions of compound based on the

graphite/polystyrene as well as the compound of updraft

humiliation temperature at 20ºC advanced compared to the

pure polystyrene has been stated by Xiao et al [40]. Now the

current learning, the spreading of expanded graphite in

epoxy medium to make expanded graphite has been

examined to disclose the situation to influence the properties

of expanded graphite/epoxy compounds.

A. Modernisation of graphite

There are four basic modification of graphite namely

graphene oxide, graphite intercalation compound, expanded

graphite and graphene. Graphite material forms in layer for

the effective use of natural graphite by means of a putty in a

polymer compound and coatings of compound have

different and distributed whole polymeric medium. Nano

graphite platelet is the elementary component found through

exfoliation of the natural chipped carbon based material also

taking a platelet breadth must be varied up to fewer than

0.34 to 100 nm, was hopeful at small price also light weight

substitute to metallic then carbon created electrically leading

to make strength aimed at leading polymer compounds [41-

42-43]. In the natural form or normal form there is not any

responsive charges collections present into the coatings and

as an outcome, material does not have the capability to

introduce single unit into the graphite arcades via charge

conversation responses such as remains conceivable aimed

at the coated silicates. Though, carbon based material stands

willingly introduced also container congregation for several

atoms, particles, metallic developments also salts among the

prolonged carbon based sheets to make carbon based

intercalation composites

B. Specification of graphene oxide, graphite based

intercalation compound, extended graphite

Graphene oxide have property to be recognized as oxide of

graphite, graphitic or graphitic acid; has generally ready via

the dealing chips of graphite with reacting mediators

therefore tropical collections have presented happening into

the graphite layer in that way wide the inter-sheet

arrangement of the graphene plates [44]. Oxide based

graphene was ready through Brodie in 1859 which naturally

includes the response of the chips of graphite via fuming of

nitric acid and potassium chlorate [45]. A quicker and

harmless technique to prepare graphene oxide via

responding without water in sulphuric acid, sodium nitrate

as well as potassium permanganate established by Hummers

and offeman and broadly tracked even at present time

[46].Graphite intercalation compounds have been formed

through the addition of microscopic sheets of diverse

biological type among the outer surface of the carbon based

congregation frame [47, 48].

Fig. 3. Groundwork of GNPs of graphite precipitate using midway

GIC step.

Fig.4 Polymerization of graphite based intercalation compound is not

dissolving in hydrocarbon. Character revised through authorization from

reference [52].

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When carbon based material like graphite (usually graphite

bisulphate was applied, though in the standard of some

graphite intercalation compound to be able to used) was

warmed previously a precarious high temperature or visible

to warm through energy also a big growth of flecks of

graphite happen beside c-alignment into the in-plane way,

starting caterpillar-like consensus charges through little

compactness and also great temperature confrontation also

this winded out manufactured goods are recognized as

prolonged graphite [49-51].

While graphene has been deliberated since 60 years,

theoretically it indicates a fresh lesson of material

specifically one particle is heavy therefore has a fast fame in

the ground of constituents’ science and Nano electronics

[53-55]. Five ways have been obtained & planned for the

grounding of graphene.

The involvement of chemical vapour admission of single

coating of graphite happening to the conversion of metal

surfaces [56, 57]. The route of subsequent layer into the

micro-mechanical graphite exfoliation and involved

cracking of the graphene after graphite by “Scotch”

adhesive tape [58]. The “Scotch” adhesive friction tape was

immersed into acetone toward discharge graphene and are

successively taken in a silicon cracker by silicon dioxide

coating on upper surface. The development of graphite has

been settled and also substrates electrically in protecting

similar to the silicon carbide [59].

V. CHARACTERISATION TECHNIQUES OF GRAPHITE

PLATELET/EPOXY COMPOSITE

A. Broad viewpoint of X-ray spreading

Broad viewpoint of x-ray spreading has been applied to

settle the building of the compound. Broad viewpoint of x-

ray spreading has been performed on a Rigaku spread

pattern using Cu Ka energy (lZ1.541 A°) employed on 40

kV and20 mA. The perusing variety have 4˚ to 60˚ by a

perusing rapidity of 0.5 ˚/min.

B. Mechanical analysis

Stretchy checks are made on an Instron 8500servo hydraulic

analysis of machine on the crosshead proportion is 0.25

mm/minute and also is equal towards the straining

proportion is in the form of 0.01 percent (%) per second.

Strain gages is used to note the straining rate. Through the

all cases only six check have been accepted.

C. Development of updraft factor

Epoxy resin have the capability to grow the thermal

coefficients and its compounds have been considered by a

strain equipment method. The thermal strain of slope against

temperature graph identifies thermal expansion coefficient

of the compound.

The updraft straining rate has been recorded on great

temperature strain devices. The devices have been joined on

the sample of following surface for Micro Measurements,

Combined standard techniques. Strain gauge interpretations

have been regulated by model of titanium silicate and also

the error owing to the decently rise of thermal production of

straining device has occupied in the account and also for

modification.

D. Composite based on nano graphite

Graphite Nanoparticles were used as strengthening in

fabrication of polymer composites to increase mechanical,

electrical and updraft effects [60]. Certain researchers

verified the mechanical properties polyethylene which have

a great concentration Nano composites reinforced through

expanded graphite [61-64]. They established that the tensile

strength increased to 18.7% when 40% expanded graphite

has been added, and the young’s modulus improved with

growth in graphite content [65]. Some researchers operated

on blending of PA6/HDPE (polyamide 6/high density

polyethylene) through changing configurations. They

described that the composition PA6/HDPE (2%) have

increased modulus, hardness and strength. [66] Since PA’s

have great attraction near water, researchers mixed

polypropylene by varying composition (0%, 10%, 20%,

30%) with carbon fiber as reinforcement. they settled that

liquid immersion & also width of enlargement reduced as

polypropylene content has been enhanced. The final stretchy

strength also elastic modulus (after saturation) in the range

of 10%, 20%, 30% PP are higher than neat PA.

Zhou et.al [67] planned the PA6 / PPS-CF (carbon fibers)

composites and stated that increase in totaling of carbon

fiber (CF) content in PA6 / PPS composite loses the impact

strength.

Li et.al [68] examined the mechanical assets of PA6-

Polyurethane (PU) slab co-polymer strengthened in a small

beaker fibers and determined that impact strength reduced

through the addition of SGF. It has been found that a lot of

work have been done on expansion of compounds polymer,

but slight work had been performed taking place the

development of the graphite reinforced polymer composite

designed for structural and bearing applications.

The objective of the research work must develop graphite

/PP66 composites and designed for tensile, impact and

ductility behavior.

E. Development and optimization of restraining

The impartial of designing composite structures with better

or optimized damping features has led to the growth of

mechanical philosophies for showing of composite damping

at the micromechanical and macro mechanical levels. Better

damping of composite materials combined with high

stiffness and strength can be understood through control of

the geometrical and mechanical properties at several levels.

1) Damping at the macro mechanical level

Macro mechanical developments in damping

consequence from changes in geometrical and/or

material properties at or above the lamina level in

composites but do not contain changes at the basic

material level.

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2) Effect of inter-laminar stress and the lamina

orientation on damping

Inter-laminar pressures generally arise on the plate

borders close to open boundaries into the

composite covers. These inter-laminar tensions

mean that the portion of the entire energy scattering

into the plate owing to inter-laminar checking.

3) Damping improvement through coupling effect

Shaking link happening in compounds is

influenced by constraints such as per fibre

alignment, loading order also shaking styles of

attention. There are two type of the main link styles

in composite laminates remain the bending twisting

link in symmetric laminates also the bending-

extensional link in anti-symmetric laminates [69].

Pratt et al. [70] has examined ordered thread

movement of designs in compounds such as

inducing extra restraining owing to pressure link

belongings. This research complicated the usage of

viscoelastic coatings which were preserved through

surrounded among fibres.

F. Combination of expanded graphite

Expanded graphite/epoxy compound has synthesized to

become dissimilar substances of expanded graphite

(3weightt%, 6weightt%, and 9weightt% to the foundation of

the weight of epoxy) over a combination of mixing

technique. To compute the quantity of epoxy and expanded

graphite have separately scattered in deionise liquid next to

ambient temperature through rousing designed for half an

hour. Expanded graphite holds-up is added to the epoxy

mixture and stirring has to be sustained for 3 hours. The

subsequent mixture has been centrifuged aimed at 15 minute

and also the subsequent model has dehydrated happening

into the furnace at 50ºC. The filled explanation of artificial

procedure has given below in Fig 5.

G. Review on milling machine operation

In milling process in which the work piece is fed past a

revolving cylindrical tool along with multiple cutter edge.

The alignment of tool has been vertical to the feed way. The

tool has been named as milling cutter and on the other hand

cutting edges has been named as teeth. Generally, surface of

plane is created by milling operation. Milling is a machining

operation which is used to machine plane, curled.

Basically the milling machines have been categorized such

as perpendicular or uneven sides through nourishing the

work piece counter to a revolving flat. Milling machine have

been also classified such as knee-type and cutter covering a

number of cutting limits. The accuracy of the milling

machine is better as compared to the parent machining

operation.

The milling machine with several cutters has been attached

on the arbor at the same time, hence growing the metal

removal rate plus permitting numerous sides to be machined

at the equivalent period as well as confirms the machining

precision. During milling operation, it has produced the

large number of operation and in this process removal of

material takes when the work has been fed preceding a

rotating cutter.

H. Process of milling operation

Milling process has a metal removal operation in which a

metal detaches through a revolving multipoint cutter which

has been mounted on the arbor of the milling machine. The

shape of the structure has been obtained through milling

operation and the unwanted materials have been removed.

Milling machine has certain main constituents, which have

been used such as column, saddle, its Base, table, knee,

arbour, over-arm and spindle. In milling operation, the

certain properties of surface have been improved such as

corrosion resistance, fatigue strength as well as creep life.

During milling operation, the surface roughness disturbs a

number of functional features of portions, like, rubbing

among two contacted portions, wearing of portion,

reflection, conduction of heat, dispensing capability and also

holding a lubrication oil, load bearing capacity, fatigue

resisting etc. Hence, the designated procedures have to be

accurate through the process and also the preferred complete

exterior has been specified.

I. Development of milling operation

It has been conceived to classify dual phases of growth of

milling machine tools and also machine centers [71]. Once the

investment has been determined to proceed benefit of the

remove non-creative period owing to statistical control and

concurrently when uprising in control of machine and structure

of machine has been perceived [72]. Afterwards in 1980,

while machining midpoints concentrated on decreasing the

lengthy arrangement and also tool alteration periods related

along with the milling procedure.

In 1980, development has been founded on the three paths that

is development of apparatuses along with additional gradations

of liberty in their gestures and also growth of manufacturing

association and also in enhancement of the goods of acerbic

ends.

Though computer aided manufacturing organizations may be

able to mechanically deliver tool routes, and also the cutting

circumstances conferring to work-part constituents, cutting

processes and cutting kinds. Though, it has been problematic to

copycat the knowledge and also abilities of operators in

choosing apparatuses, cutting circumstances.

J. Literature review in milling operation

Nitin B. Katrodiya et al. [73] provides an evidence around

the surface roughness which lies on numerous constraint

such as depth of cut (D), feed rate, speed of spindle (S) as

well as acerbic route which has been monitored through

device of tool.

The pioneer researchers are working in the area of

improving the surface rougness which occurs during the

milling operation. Now, various acerbic pathway has unique

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indicator and twisting has been measured by way of reaper

route plans.

The planning of cutter path strategies has been effected to

the external texture of the labour portions.

Kannan.S et al. [74] provide the concept of work which has

enlighten the limit effect happening in material removal rate

(MRR) as well as in surface Roughness of aluminum.

To improve in productivity and quality of portion,

considering the process of milling parameter like feed rate,

speed of spindle as well as in depth of cut. In face milling

the association among the input plus output response

constituent has been aimed to enhance the performance of

milling operation.

VI. DISCUSSION

A. Surface possessions of NG/Epoxy compound

Surface properties of compound material has been observed

through the use of Rame-Hart goniometer. The values

obtained from the use of Rame-Hart goniometer has been

used to compute based on the contact angle among the

liquid as well as in solid for well-known standards of

surface free energy and it has been used to get the full

features and the accurate information of surface energy.

B. Mechanical and Thermal solidity based on the natural

graphite/epoxy content of compound

The mechanical interfacial goods of the natural graphite

compounds rendering to the substance of natural graphite is

study via splintering robustness dimensions to survey crack

development of confrontation.

When the content of natural graphite has increased, the

thermal stability of NG/Epoxy compound have enhanced.

Due to the confrontation of heat, the thermal decomposition

of natural graphite/epoxy compound material is difficult.

C. Effect of thermal conductivity of the NG/Epoxy

composite

The thermal conductivity of natural graphite and epoxy

compound has been achieved with the use of advanced laser

flash technique.

Laser flash technique has been used to determine the

thermal conductivity of material through the multiplication

of specific heat as well as density, through determining the

thermal diffusivity of the model.

D. Preparation of expanded graphite/Epoxy compound

Expanded graphite/epoxy compound has synthesized to

become dissimilar substances of expanded graphite (3

weight%, 6 weight%, and 9 weight% to the foundation of

the weight of epoxy) over a combination of mixing

technique.

To compute the quantity of epoxy and expanded graphite

have separately scatter in deionize liquid next to ambient

temperature through rousing designed for half an hour.

Expanded graphite hold-up is add to the epoxy mixture and

stirring has sustained for 3 hour.

The subsequent mixture has been centrifuged aimed at 15

minute and also the subsequent model has dehydrated

happening into the furnace at 50ºC. The filled explanation of

artificial procedure has given below in Fig.5.

Dry, 24 h H2SO4+HNO3

Graphite Anhydrous Functionalized

Graphite stirring, 24 h Graphite

Heat, 900˚c

(1 minute)

Epoxy/expanded graphite Expanded graphite

Nano composite

Fig.5 Sequence of making the expanded graphite/epoxy compound.

VII. CONCLUSION

In this paper the study has been made to enhance the

mechanical as well as thermal properties with the use of

natural graphite as well as in epoxy compound which is

familiar to environment.

• The survey reveals that very small quantity of work has

been performed on graphite composites and the area

still lacks the various machining sector.

• Moreover, the Graphite composites exhibits better

machining characteristics as compared to other

traditional materials and it can be seen from the

previous state of art.

• Heat resistance is the main reason to enhance the

thermal stability of natural graphite and it has a great

thermal stability as compared to the epoxy composite.

• Mixing method is used to prepare the solution of

expanded graphite and epoxy composite and to find out

the intercalation of expanded graphite with epoxy

matrix. • Increasing the expanded graphite content; the

properties of epoxy such as thermal, electrical and

mechanical are enhanced. As we keep on increasing the

percentage of expanded graphite the thermal stability of

epoxy also starts to improve.

• The strong interfacial adhesion of the expanded

graphite along with epoxy medium has been used to

enhance the mechanical as well as thermal properties.

• The expanded graphite sheet spread over the epoxy

matrix to convert the epoxy resin into the electrically

conductive materials. Graphite nanoparticle has been

used to strengthen the fabrication of composite polymer

to increase the updraft, mechanical and electrical effect

of compound.

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