Carbon black-reinforced polymer composites: multifunctional advancements, characterization, and industrial applications

Yahaya  Musa; Vaibhav Jaiswal; Dhirendra Kumar Verma; Aliyu  Sale

doi:10.62638/ZasMat1466

Authors

Yahaya Musa Gusau Department of Mechanical Engineering, Sharda School of Engineering and Technology, Sharda University, Greater Noida U.P., India Author https://orcid.org/0009-0007-4789-7395
Vaibhav Jaiswal Department of Mechanical Engineering, Sharda School of Engineering and Technology, Sharda University, Greater Noida U.P., India Author https://orcid.org/0000-0002-3954-3198
Dr. Dhirendra Kumar Verma Department of Mechanical Engineering, Sharda School of Engineering and Technology, Sharda University, Greater Noida U.P., India Author https://orcid.org/0000-0002-8095-5055
Aliyu Sale Federal College of Education Technical Gusau, Zamfara State, Nigeria Author https://orcid.org/0009-0005-3181-0051

DOI:

https://doi.org/10.62638/ZasMat1466

Abstract

Carbon black (CB) has emerged as a transformative additive in polymer matrix composites (PMCs), offering unparalleled enhancements in mechanical, electrical, and thermal properties. This comprehensive review synthesizes recent advancements in CB-reinforced composites, focusing on their multifunctional roles in aerospace, automotive, electronics, and energy applications. Key findings highlight CB’s ability to achieve electrical percolation at ultralow loadings (0.58 wt%), improve tensile strength by 15–40%, and enable electromagnetic interference (EMI) shielding exceeding 150 dB in hybrid systems with carbon nanotubes (CNTs) or graphene. The review systematically examines CB’s reinforcement mechanisms, including its fractal aggregate structure, interfacial adhesion, and synergistic effects in hybrid composites. Critical applications such as lightweight EMI shielding, UV-resistant coatings, and conductive adhesives are discussed, alongside industrial challenges like dispersion uniformity and long-term durability. Emerging trends in sustainable alternatives (e.g., bio-derived CB, recycled CB from tires) and advanced manufacturing (e.g., 3D printing) are highlighted as pathways to address environmental concerns and scalability limitations. Despite its versatility, challenges persist in optimizing CB-polymer interfaces, mitigating health risks, and standardizing processing techniques. Future research directions emphasize AI-driven material design, surface functionalization, and circular economy approaches to unlock CB’s full potential in next-generation smart composites. This review underscores CB’s pivotal role in advancing high-performance materials while calling for interdisciplinary collaboration to bridge laboratory innovations with industrial adoption.

Keywords:

carbon black, polymer composites, EMI shielding, hybrid nanocomposites, electrical conductivity, sustainable materials

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