Comprehensive Preparation, Structural Characterization, and Performance Evaluation of Graphite‐Enhanced Polymer Nanocomposites: Investigating Their Mechanical, Thermal, and Electrical Properties for Advanced Material Applications

ABSTRACT The present study focuses on the synthesis, characterization, and mechanical evaluation of polyaniline (PANI), graphite nanoparticles, and their hybrid PANI/graphite nanocomposites for potential applications in high‐performance epoxy‐based materials. X‐ray diffraction (XRD) analysis confirmed the crystalline structure of graphite with a sharp (002) peak at 2 θ = 26.544°, while PANI displayed peaks indicative of an orthorhombic semi‐crystalline structure. The PANI/graphite composite retained characteristic peaks of both components, signifying successful incorporation without disrupting their intrinsic structures. FTIR spectra further validated the presence of functional groups associated with PANI's benzenoid and quinoid units and minimal surface functionality in graphite. Morphological analysis using FESEM revealed graphite's layered flake‐like texture and PANI's porous, agglomerated network, while the hybrid composite exhibited homogeneous dispersion and strong interfacial bonding. Mechanical testing demonstrated significant improvements in tensile strength with increasing filler content up to 1.5 wt%, with the hybrid system outperforming individual fillers due to synergistic effects, reaching a maximum strength of 72.61 ± 3.14 MPa. Beyond 1.5 wt%, performance declined due to filler agglomeration. FESEM fracture analysis corroborated these findings, highlighting optimal filler dispersion at 1.5 wt%. These composites show promise for applications in structural materials, electromagnetic shielding, and energy storage devices such as supercapacitor electrodes, where enhanced conductivity and mechanical reinforcement are critical.