RESEARCH Synthesis, morphology, structural, and rheological studies of Fe 0.01 Al 0.5 La. 0.01 Zn 0.98 O-based polyaniline composite materials M. Sohail 1 & M. Saleem Khan 2 & Muhammad Omer 1 & Ihsan Ullah Marwat 1 & Noor Saeed Khattak 3 & Sana Ullah Khan 4 & Zakir Ullah 5 & Sami Ur Rahman 2 Received: 27 July 2017 /Revised: 12 April 2018 /Accepted: 17 May 2018 # Australian Ceramic Society 2018 Abstract In the present study, mixed-metal ceramic Fe 0.01 Al 0.5 La. 0.01 Zn 0.98 O particles and their composites with polyaniline (PANI) were prepared via sol-gel and in situ free-radical polymerization techniques, respectively. Particles and composite formation was confirmed by FT-IR spectroscopy. SEM studies showed the Fe 0.01 Al 0.5 La. 0.01 Zn 0.98 O particle’ s homogeneous dispersion in the polymer matrix. Ceramic particles were found to be in microdimensions. XRD analysis confirmed crystallite size in the range from 22 to 28 nm. Extensive rheological characterization was performed to check the durability of the materials for possible applications. Flow-curve tests suggested that the prepared materials are non-Newtonian (shear thinning) in nature. Increasing temperature have no appreciable effect on the viscosity which confirmed the mechanical stability of the materials. Based on frequency sweep test findings, the mechanical rigidity of the polymer has been enhanced (G′ = 2 × 10 2- 5.22 × 10 3 Pa) by the introduction of ceramic particles. Conversely, creep compliance has been decreased considerably. Keywords PANI composite . XRD . Rheology Introduction The integration of inorganic fillers especially ceramic particles into a polymer matrix is of significant industrial importance. These reactive organo-ceramic composites have desirable properties adjusted to specific applications [1]. For the first time, these composites were produced in 1981 [2] to increase the flexural strength of cement. It was investigated that the combination of cement and polyvinyl alcohol (PVA) under high shear mixing produced hardened composites having flexural strengths of about 200 MPa. Henceforth, an efficient number of combinations of fillers and polymers have been reported in literature [1, 3]. In the composites, both compo- nents (organic/inorganic) offer distinct features while modify- ing and reinforcing each other. Ceramic-based polymer com- posites can be synthesized at ambient temperature in the form of thick pastes that become hardened materials having similar characteristics like fired ceramics after low-temperature heat treatment. During high shear procedure, the physical and/or chemical interactions between ceramic and polymer phases result in the production of paste with enhanced rheological properties [3]. With progression of interactions, the paste be- comes harder and its viscosity increases with time. Thus, it is important to recognize that during processing, how the rheol- ogy of paste changes with time. Regardless of the type of ceramic used for strengthening the polymer matrix, rheological properties of the composite mostly depend on ceramic particle loading, their dispersion, and orientation in the polymer matrix and other processing parameters. It has been observed that with an increase in well-dispersed particle concentration in the polymer ma- trix, mechanical properties of composite increased [4]. Monolithic inorganic filler (ceramic) does not bear all re- quired mechanical and other functional features. Therefore, * M. Sohail msohail2000@gmail.com 1 Institute of Chemical Sciences, University of Swat, Mingora, Khyber Pakhtunkhwa, Pakistan 2 National Center of Excellence in Physical Chemistry, University of Peshawar, Peshawar, Pakistan 3 Center for Material Sciences, Islamia College University, Peshawar, Pakistan 4 Department of Chemistry, Women University Swabi, Swabi, Khyber Pakhtunkhwa, Pakistan 5 Department of Physics, University of Malakand, Lower Dir, Khyber Pakhtunkhwa 18800, Pakistan Journal of the Australian Ceramic Society https://doi.org/10.1007/s41779-018-0207-2