Three-dimensional hollow graphene–metallic nanocomposite foam manufactured by polymer-templated electrochemical co-deposition

Due to its outstanding electrical, thermal, and mechanical properties, graphene (Gr) has been extensively studied in recent years as nanofiller for metallic nanocomposites. However, the manufacture of metallic nanocomposites with Gr as a nanofiller is still challenging especially for three-dimensional (3D) architectures. This study explores an electrochemical co-deposition process to manufacture Gr–metal nanocomposites at ambient conditions. Utilizing a polymer foam as the template, a 3D graphene–nickel (Gr–Ni) foam is fabricated by this simple, cost effective and scalable technique. The Gr–Ni nanocomposite foam is characterized by electron microscopy, Raman spectroscopy and mechanical testing. It is revealed that both the elastic modulus and the strength of the foam can be improved after incorporation of Gr. Measurement showed that with only 10 μm coating thickness, the mechanical properties of hollow Gr–Ni foam will be improved about 35% more than the pure hollow Ni foam. The polymer-templated co-deposition method is a potential process to fabricate Gr nanocomposites into more architectures.