Flexible graphite foils with varying thicknesses (S = 282 ± 5 μm, M = 494 ± 7 μm, L = 746 ± 8 μm) and an initial density of 0.70 g/cm3 were obtained using the nitrate method. The specific electrical and thermal conductivity of these foils were investigated. As the density increased from 0.70 g/cm3 to 1.75 g/cm3, the specific electrical conductivity increased from 69 to 192 kS/m and the thermal conductivity increased from 109 to 326 W/(m·K) due to the rolling of graphite foils. The study showed that conductivity and anisotropy depend on the shape, orientation, and contact area of thermally expanded graphite (TEG) mesoparticles (mesostructural factor), and the crystal structure of nanocrystallites (nanostructural factor). A proposed mesostructural model explained these increases, with denser foils showing elongated, narrowed TEG particles and larger contact areas, confirmed by electron microscopy results. For graphite foils 200 and 750 μm thick, increased density led to a larger coherent scattering region, likely due to the rotation of graphite mesoparticles under mechanical action, while thinner foils (<200 μm) with densities > 1.7 g/cm3 showed increased plastic deformation, indicated by a sharp reduction in the coherent scattering region size. This was also evident from the decrease in misorientation angles with increasing density. Rolling reduced nanocrystallite misorientation angles along the rolling direction compared to the transverse direction (TD) (for 1.75 g/cm3 density ΔMA = 1.2° (S), 2.6° (M), and 2.4° (L)), explaining the observed anisotropy in the electrical and mechanical properties of the rolled graphite foils. X-ray analysis confirmed the preferred nanocrystallite orientation and anisotropy coefficients (A) using Kearns parameters, which aligned well with experimental measurements (for L series foils calculated as: A0.70 = 1.05, A1.30 = 1.10, and A1.75 = 1.16). These calculated values corresponded well with the experimental measurements of specific electrical conductivity, where the anisotropy coefficient changed from 1.00 to 1.16 and mechanical properties varied from 0.98 to 1.13.

The physical and mechanical properties and structural condition of flexible graphite foils produced by processing natural graphite with nitric acid, hydrolysis, thermal expansion of graphite and subsequent rolling were studied. The processes of obtaining materials and changing their characteristics has been thoroughly described and demonstrated. The structural transformations of graphite in the manufacture of foils were studied by X-ray diffraction analysis (XRD) and transmission electron microscopy (TEM). A decrease in the average size of the coherent scattering regions (CSR) of nanocrystallites was revealed during the transition from natural graphite to thermally expanded graphite from 57.3 nm to 20.5 nm at a temperature of 900 °C. The rolling pressure ranged from 0.05 MPa to 72.5 MPa. The thickness of the flexible graphite foils varied from 0.11 mm to 0.75 mm, the density-from 0.70 to 1.75 g/cm3. It was shown that with an increase in density within these limits, the compressibility of the graphite foil decreased from 65% to 9%, the recoverability increased from 5% to 60%, and the resiliency decreased from 10% to 6%, which is explained by the structural features of nanocrystallites. The properties\' anisotropy of graphite foils was studied. The tensile strength increased with increasing density from 3.0 MPa (ρ = 0.7 g/cm3) to 14.0 MPa (ρ = 1.75 g/cm3) both in the rolling direction L and across T. At the same time, the anisotropy of physical and mechanical properties increased with an increase in density along L and T to 12% with absolute values of 14.0 MPa against 12.5 MPa at a thickness of 200 μm. Expressed anisotropy was observed along L and T when studying the misorientation angles of nanocrystallites: at ρ = 0.7 g/cm3, it was from 13.4° to 14.4° (up to 5% at the same thickness); at ρ = 1.3 g/cm3-from 11.0° to 12.8° (up to 7%); at ρ = 1.75 g/cm3-from 10.9° to 12.4° (up to 11%). It was found that in graphite foils, there was an increase in the coherent scattering regions in nanocrystallites with an increase in density from 24.8 nm to 49.6 nm. The observed effect can be explained by the coagulation of nanocrystallites by enhancing the Van der Waals interaction between the surface planes of coaxial nanocrystallites, which is accompanied by an increase in microstrains. The results obtained can help discover the mechanism of deformation of porous graphite foils. The obtained results can help discover the deformation mechanism of porous graphite foils. We assume that this will help predict the material behavior under industrial operating conditions of products based flexible graphite foils.