Preparation of high-value pitch-based carbon fibres (CFs) from mesophase pitch precursor is of great importance towards low-cost CFs. Herein, we developed a method to reduce the cost of CFs precursor through incorporating high loading of coal tar pitch (CTP) into polyacrylonitrile (PAN) polymer solution. The CTP with a loading of 25% and 50% was blended with PAN and their spinnability was examined by electrospinning process. The effect of CTP on thermal stabilization and carbonisation of PAN fibres was investigated by thermal analyses methods. Moreover, electrospun PAN/CTP fibres were carbonised at two different temperatures i.e., 850 °C and 1200 °C and their crystallographic structures of resulting such low-cost PAN/CTP CFs were studied through X-ray diffraction (XRD) and Raman analyses. Compared to pure PAN CFs, the electrical resistivity of PAN/25% CTP CFs significantly decreased by 92%, reaching 1.6 kΩ/sq. The overall results showed that PAN precursor containing 25% CTP resulted in balanced properties in terms of spinnability, thermal and structural properties. It is believed that CTP has a great potential to be used as an additive for PAN precursor and will pave the way for cost-reduced and high-performance CFs.

The most known analogue of graphene, molybdenum disulfide (MoS₂) nanosheet, has recently captured great interest because it can present properties beyond graphene in several high technological applications. Nonetheless, the lack of a feasible, sustainable, and scalable approach, in which synthesizing and functionalization of 2H-MoS₂ nanosheets occur simultaneously, is still a challenge. Herein, a hydrothermal treatment has been utilised to reduce the effect of breaking mechanisms on the lateral size of produced nanosheets during the ball milling process. It was demonstrated that the hydrothermal pre-treatment led to the initial intercalation of an organic molecule such as 4,4′-diaminodiphenyl sulfone (DDS) within the stacked MoS₂ sheets. Such a phenomenon can promote the horizontal shear forces and cause sliding and peeling mechanisms to be the dominated ones during low energy ball milling. Such combined methods can result in the production of 2H functionalized MoS₂ nanosheets. The resultant few layers showed an average lateral dimension of more than 640 nm with the thickness as low as ~6 nm and a surface area as high as ~121.8 m²/g. These features of the synthesised MoS₂ nanosheets, alongside their functional groups, can result in fully harnessing the reinforcing potential of MoS₂ nanosheets for improvement of mechanical properties in different types of polymeric matrices.

Process parameters, especially in the thermal stabilization of polyacrylonitrile (PAN) fibers, play a critical role in controlling the cost and properties of the resultant carbon fibers. This study aimed to efficiently handle the energy expense areas during carbon fiber manufacturing without reducing the quality of carbon fibers. We introduced a new parameter (recirculation fan frequency) in the stabilization stage and studied its influence on the evolution of the structure and properties of fibers. Initially, the progress of the cyclization reaction in the fiber cross-sections with respect to fan frequencies (35, 45, and 60 Hz) during stabilization was analyzed using the Australian Synchrotron-high resolution infrared imaging technique. A parabolic trend in the evolution of cyclic structures was observed in the fiber cross-sections during the initial stages of stabilization; however, it was transformed to a uniform trend at the end of stabilization for all fan frequencies. Simultaneously, the microstructure and property variations at each stage of manufacturing were assessed. We identified nominal structural variations with respect to fan frequencies in the intermediate stages of thermal stabilization, which were reduced during the carbonization process. No statistically significant variations were observed between the tensile properties of fibers. These observations suggested that, when using a lower fan frequency (35 Hz), it was possible to manufacture carbon fibers with a similar performance to those produced using a higher fan frequency (60 Hz). As a result, this study provided an opportunity to reduce the energy consumption during carbon fiber manufacturing.