Multiparameter Structural Optimization of Single-Walled Carbon Nanotube Composites: Toward Record Strength, Stiffness, and Toughness

Efficient coupling of mechanical properties of SWNTs with the matrix leading to the transfer of unique mechanical properties of SWNTs to the macroscopic composites is a tremendous challenge of today's materials science. The typical mechanical properties of known SWNT composites, such as strength, stiffness, and toughness, are assessed in an introductory survey where we focused on concrete numerical parameters characterizing mechanical properties. Obtaining ideal stress transfer will require fine optimization of nanotube-polymer interface. SWNT nanocomposites; were made here by layer-by-layer (LBL) assembly with poly(vinyl alcohol) (PVA), and the first example of optimization in respect to key parameters determining the connectivity at the graphene-polymer interface, namely, degree of SWNT oxidation and cross-linking chemistry, was demonstrated. The resulting SWNT-PVA composites demonstrated tensile strength (sigma(ult)) = 504.5 +/- 67.3 MPa, stiffness (E) 15.6 +/- 3.8 GPa, and toughness (K) = 121.2 +/- 19.2 J/g with maximum values recorded at sigma(ult), = 600.1 MPa, E 20.6 GPa, and K = 152.1 J/g. This represents the strongest and stiffest nonfibrous SWNT composites made to date outperforming other bulk composites by 2-10 times. Its high performance is attributed to both high nanotube content and efficient stress transfer. The resulting LBL composite is also one of the toughest in this category of materials and exceeding the toughness of Kevlar by 3-fold. Our observation suggests that the strengthening and toughening mechanism originates from the synergistic combination of high degree of SWNT exfoliation, efficient SWNT-PVA binding, crack surface roughening, and fairly efficient distribution of local stress over the SWNT network. The need for a multiscale approach in designing SWNT composites is advocated.