Graphene-enhanced epoxy composites: A comprehensive review of dispersion mechanisms, processing strategies, property optimization, characterization and sustainable innovations

Graphene has emerged as one of the most promising materials for enhancing the properties of polymer composites, particularly epoxy resins. In order to attain the greatest benefits of graphene nanoparticles in the production of composite matrix systems for industrial applications, it is crucial to know which aspects can influence the final material qualities. Among these, nanoparticle dispersion plays a crucial role in the mechanical properties of polymer nanocomposites. The dispersion of graphene nanofillers is not a straightforward process since they tend to agglomerate due to van der Waals interactions. To promote de-agglomeration, various dispersion technologies are available. A survey of the literature regarding dispersion strategies and the accompanying mechanisms constitutes the core of the present review. Starting with a basic overview of difficulties associated with charging matrix materials with graphene and a short description of the properties of graphene, the review focuses on mechanisms governing graphene dispersion in epoxy. Furthermore, the physical and chemical techniques promoting effective dispersion are examined. Possible approaches for integrating dispersive technologies and adjusting dispersion quality are also discussed. Finally, the relationship between dispersion quality and the properties of graphene-epoxy composites and the characterization methods used to evaluate the quality of dispersion are critically analyzed. This comprehensive review highlights the advances, challenges, and future directions in achieving optimal dispersion of graphene in epoxy composites, emphasizing its significance for the development of high-performance materials.