Microwave-induced hierarchical iron-carbon nanotubes nanostructures anchored on polypyrrole/graphene oxide-grafted woven Kevlar® fiber

Iron-carbon nanotube (Fe-CNT) nanostructures were synthesized in 15–30 s through the microwave irradiation of woven Kevlar® fibers (WKFs) deposited with either polypyrrole (PPy) or polypyrrole/graphene oxide (GO). Microwave-induced growth of Fe-CNT on the base fibers is a simple technique and has not been previously reported using WKF as a substrate. This method of forming composites avoids the difficulties associated with obtaining a homogeneous dispersion of CNT in a surrounding matrix material. Iron-decorated CNTs were synthesized on WKF and polyester resin (PES) via vacuum-assisted resin transfer molding. Substantial improvements in tensile strength (upto 122.57%) and moduli (upto 89.82%) were observed for Fe-CNTs grown on the WKF/PES composites. The impact response and in-plane shear strength were also significantly enhanced compared to bare WKF/PES composites. In situ polymerization of pyrrole on WKF altered the electrically insulating behavior of Kevlar, creating a conductive material. Fe-CNT/PPy-coated WKF/PES exhibited the highest electrical conductivity. This proposed approach for growing Fe-CNTs constitutes a novel and economical means of developing high-performance WKF/CNT composites with enhanced mechanical properties and electrical conductivity.