Simultaneous in situ reduction, self-alignment and covalent bonding in graphene oxide/epoxy composites

Graphene oxide (GO)/waterborne epoxy (EP) composites are prepared using an easy, all aqueous, in situ polymerization method. GO is reduced in situ using hydrazine to achieve highly stable reduced graphene oxide (rGO)/EP dispersions, leading to the formation of composites with a self-aligned layered structure and highly anisotropic properties between the direction of alignment and that perpendicular to it. The strong covalent bonding between the epoxy and rGO and the highly aligned, ultralarge rGO sheets give rise to a remarkable percolation threshold of 0.12 vol.%, as well as much improved mechanical, electrical and thermal properties of the composites in the alignment direction. They outperform those containing GO sheets that are bonded to the epoxy matrix through a weaker π–π stacking mechanism.