Role of Electrochemically Exfoliated Graphene in Property Enhancement of Electrodeposited Copper Nanocomposites

The present investigation is an attempt to modify the properties of copper with the incorporation of graphene (few-layer graphene nano-sheets (FLGNs)) as reinforcements so that intrinsic limits of copper such as low hardness and susceptibility to corrosion can be addressed. The FLGNs were produced by electrochemical intercalation and exfoliation of graphite rods with electrolytes (0.5 M HClO₄ and a combination of 0.5 m HClO₄ and HNO₃ at varying concentrations). Increasing HNO₃ concentration has accelerated the exfoliation rate, reducing overall processing time, while oxidation activity is simultaneously intensified. This has increased the functionalization of the sheets which was confirmed by Raman as well as UV–vis spectroscopy and was complemented by structural and morphological studies. The synthesized FLGNs are then integrated into copper sulfate solution at varying compositions (0.05, 0.1, and 0.3 g L⁻¹) to form copper-graphene nanocomposites through electrodeposition. It was observed that the 0.3 g L⁻¹ nano-graphene reinforcement increased the hardness by 199.08 HV due to significant hardening in the thin film. Corrosion studies in NaCl solutions revealed positive effects where the corrosion rate decreased from 0.0147 to 0.0101 mm per year with increasing graphene concentrations. 0.3 g L⁻¹ Cu-Gr composite exhibited the most pronounced enhancements, underscoring the potential of graphene-reinforced copper nanocomposites for advanced material science applications. The study holds significant potential for developing lightweight, durable, and high-performance materials for advanced applications through the synthesis of composites by electrodeposition route.