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High-density polyethylene (HDPE) and polypropylene (PP) blends are widely used in industries requiring mechanically durable materials, yet the impact of processing parameters on blend performance remains underexplored. This study investigates the influence of blending sequence and screw speed on the properties of blends of HDPE and PP filled with 1.25 wt.% graphene nanoplatelets (GNPs). Changes in crystallization behaviour, tensile strength, and viscoelastic responses with blending sequence are studied. The addition of GNP increases the crystallization temperature (Tc) of PP in the PE/PP blend by 4 °C when GNP is pre-mixed with PE to form (PE+GNP)/PP blends. In contrast, when GNP is pre-mixed with PP to create (PP+GNP)/PE blends, the Tc of PP rises by approximately 11 °C, from 124 °C for the neat PE/PP blend to 135 °C. On the other hand, the Tc of PE remains unchanged regardless of the blending sequence. XRD patterns reveal the impact of blending regime on crystallinity, with GNP alignment affecting peak intensities confirming the more efficient interaction of GNPs with PP when premixed before blending with PE, (PP+GNP)/PE. Tensile moduli are less sensitive to the changes in processing, e.g., screw speed and blending sequence. In contrast, elongation at break and tensile toughness show distinct variations. The elongation at the break of the (PP+GNP)/PE blend decreases by 30% on increasing screw speed from 50 to 200 rpm. Moreover, the elongation at the break of (PE+GNP)/PP prepared at 100 rpm is ~40% higher than that of the (PP+GNP)/PE. (PE+GNP)/PP displays a 'quasi-co-continuous' morphology linked to its higher elastic modulus G′ compared to that of the (PP+GNP)/PE blend. This study highlights the importance and correlation between processing and blend properties, offering insights into fine-tuning polymer composite formulation for optimal performance. [ABSTRACT FROM AUTHOR]

This study demonstrates an all-graphene, additive-free, aqueous-based ink for direct ink writing (DIW) to 3D-print functional aerogels for applications in electronics and electromagnetic interference (EMI) shields. We employ a two-step electrochemical method with a specially designed intercalation step that controls the surface functionality of graphene nanosheets. Comprehensive characterization reveals the significant impact of the physicochemical properties of graphene nanosheets on homogeneity, rheology, electrical conductivity, and EMI shielding effectiveness (SE). A critical observation is that rheology alone is insufficient to predict the printability of two-dimensional particulate systems, while ink homogeneity, dictated by inter-sheet interactions, plays a vital role. By focusing on optimizing intercalation conditions, we find that phosphoric acid treatment is most effective in enhancing both printability and conductivity, achieving an electrical conductivity of 158 S cm−1 and an EMI SE of 50 dB (at 50 μm thickness) without requiring any post-processing reduction. Systematic experiments with varying durations of phosphoric acid intercalation establish that a 10-minutes treatment produces inks with superior 3D printing fidelity. This innovative approach to graphene ink production enables rapid, continuous, and large-scale manufacturing of lightweight, porous materials, avoiding the need for environmentally harmful reductant chemistries or high-temperature processing. Furthermore, eliminating the reduction step in the fabrication process aligns with industrial demands for energy-efficient production processes and high output rates, marking a significant advancement in the field of materials science and offering promising prospects for applying graphene-based inks in advanced manufacturing technologies. [ABSTRACT FROM AUTHOR]