In this work, hybrid polypropylene (PP)-based composites
reinforced
with graphene nanoplatelets (GnPs) and glass fiber (GF) were fabricated
by injection molding to elucidate how the hybrid approach can produce
synergistic effects capable of achieving properties and functionalities
not possible in biphasic composites. Synergism between the reinforcements
translated to improved mechanical performance, which was attributed
to the chemically and/or electrostatically assembled hierarchical
structure that facilitates load transfer at the interface while simultaneously
tailoring the crystalline microstructure of the matrix by inducing
transcrystallization and β-crystal formation. It was demonstrated
that there exists an optimal concentration of 0.5 wt % GnP, producing
the greatest mechanical properties and synergistic effect, corresponding
to the highest degree of crystallinity (∼6% greater than Neat
PP) and peak formation of β-crystals within the PP matrix. The
greatest synergistic effect was found to be ∼52 and ∼39%
for the specific tensile strength and flexural strength, respectively.
The same optimal concentration of GnPs was found to produce the highest
synergistic effect for thermal conductivity of ∼68% due to
the volume exclusion effect induced by the GFs combined with the higher
crystallinity of the microstructure, promoting the formation of thermally
conductive pathways. Ultimately, the mechanisms contributing to the
synergistic effect presented in this work can be used to maximize
the performance of hybrid composite systems, giving them the potential
to be tailored for a variety of high-performance industrial applications
to meet the rising demands for ultra-strong, thermally conductive,
and lightweight materials.