Microwave-assisted graphene intermediates for carbon fiber reinforced composite cylinders: achieving sustainability through state-of-the-art graphene and related materials

Recent research has focused on carbon fiber/epoxy laminate-based (CFRP) hydrogen storage tanks (HSTs), which offer superior structural strength, reduced weight, and enhanced safety. In this context, Graphene and Related Materials (GRMs) have emerged as promising reinforcements, enhancing the mechanical strength of the carbon fiber/epoxy laminates. However, a key challenge remains in scaling up graphene production for cost-effective, high-volume manufacturing. This study explores the potential of novel Microwave-assisted Graphene Intermediates (MGIs) as a sustainable alternative to commercial graphene materials for carbon fiber/epoxy composites. MGIs can drastically reduce the production time and cost of 2D materials. Notably, significant improvements in short beam shear strength (SBSS) were observed with MGI (∼68.9 ± 0.5 MPa) compared to bottom-up graphene materials (BGM1-64.7 ± 1.4 MPa), (BGM2-62.7 ± 1.4 MPa), and top-down graphene material (TGM-62.3 ± 1.0 MPa). Furthermore, low-velocity impact testing revealed that the MGI variant achieved superior performance with a peak force of 2.57 kN (∼25% enhancement) and absorbed energy of 13.3 J (∼14% improvement). Multi-criteria decision-making analysis further confirmed MGI as the top-ranked reinforcement among all tested GRMs, underscoring its superior mechanical performance and competitive market potential. This demonstrates MGI as a cost-effective and scalable alternative for the cost-effective and sustainable design of carbon fiber/epoxy laminate-based HSTs.