The effect of initial morphology on the mechanical properties of ultra-high molecular weight polyethylene

Studies of the physical and mechanical properties of melt crystallized ultra-high molecular weight polyethylene morphologies from melts with different thermal histories indicate that their properties depend on the degree of fusion of the powder particles during their processing and can be enhanced by heating the polymer above 220°C. The degree of cohesion of the powder particles and their initial morphology also have a significant effect on the deformability of the polymer in the solid state forming methods used to prepare high modulus and strength products.     

Effects of reactive melt mixing on the morphology and thermal behavior of linear low-density polyethylene/rubber blends

Linear low-density polyethylene (LLDPE)/polybutadiene (PB) and LLDPE/poly(styrene-b-butadiene-b-styrene) (SBS) binary blends were prepared by simple melt mixing or by reactive blending in the presence of a free-radical initiator, and for comparison, pure LLDPE was treated under the same conditions with a comparable free-radical initiator concentration. The effect of the reactive melt mixing on the morphology of the blends was studied with transmission electron microscopy, and the corresponding particle size distributions were analyzed and compared to highlight the effects of the crosslinking and grafting phenomena. Thermal properties of the obtained materials were investigated with differential scanning calorimetry and dynamic mechanical thermal analysis (DMTA). In particular, the effect of the reactive mixing parameters on the amorphous phase mobility was investigated. The influence of the chemical modification on the crystallization behavior of LLDPE, neat and blended with PB and SBS, was also studied with dynamic and isothermal differential scanning calorimetry tests, and the isothermal thermograms were analyzed in light of the Avrami equation. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Crystallization,structure, morphology,and properties of linear low-density polyethylene blends made with different comonomers

Linear low-density polyethylene (LLDPE) 7042, which has a butene comonomer, is widely used but has poor tear and dart strengths. For practical applications, small amounts of other materials can be blended with 7042 to effectively improve its properties. In this study, four blend resins and films (cast and compressed films) were prepared by blending 7042 with four LLDPEs (2045G, 9030, 23F, and 9085) in 8:2 ratios. The results indicated that after blending 2045G, 23F, or 9030 with 7042, the crystallization ability of the three blends was significantly suppressed and crystal size decreased. Moreover, the molecular chain can pass though more lamellar stacks in the blends, leading to an increased tie-chain concentration. Therefore, the tear and dart impact strength of the blend films improved. In contrast, the crystallization ability of the 7042/9085 blend was only slightly suppressed and did not significantly impact its properties. These findings contribute to our understanding of the relationship between material structures and properties, demonstrating that LLDPE blends can be used to improve the tear and dart strengths of 7042.     

Morphological studies of oriented ultra-high molecular weight polyethylene with enhanced planar mechanical properties

Ultra-high molecular weight polyethylene films prepared by melt flow crystallization under torsional flow conditions were characterized by wide angle (WAXS) and small angle (SAXS) diffraction techniques and scanning electron microscopy (SEM). The films had a fibrillar morphology in which lamellae having an average fold period of 650Å were stacked with their c-axis along the circular flow lines. X-ray analysis showed that the a and b-axes were preferentially oriented along the thickness and radial directions of the sample.     

Mechanical properties and morphology of high-density polyethylene/linear low-density polyethylene blend

The binary blend of high-density polyethylene (HDPE) and linear low-density polyethylene (LLDPE) in the range of composition from 100% HDPE to 100% LLDPE has been investigated for tensile and flexural properties and the morphology in the deformed state on tensile fracture. Tensile properties (initial modulus, yield stress, and elongation-at-yield, ultimate tensile strength and elongation-at-break, and work of yield and work of rupture) and flexural properties (flexural modulus and flexural yield stress) are studied as a function of blend composition. Behavior, in terms of these properties, is distinguishable in three zones of blend composition, viz. (i) HDPE-rich blend, (ii) LLDPE-rich blend, and (iii) the middle zone. In zones (i) and (ii), the variations of these properties are more or less linear, whereas in the middle region [i.e., zone (iii)], there is a reversal of trends in variation or sometimes a behavior opposite to the expected one. The results are explained on the basis of the effects of cocrystallization and the presence of octene-containing segments in the amorphous phase. Scanning electron micrographs of the tensile fracture surfaces are presented to illustrate the occurrence of transverse bands interconnecting the fibrils.     

Elongation viscosity estimates of linear low-density polyethylene/ low-density polyethylene blends

The elongational viscosity (EV) of two series of linear low-density polyethylene/low-density polyethylene blends was estimated using an entry flow analysis. The difference, t ? n, between the power law index t of the elongational viscosity and the power law index n of the viscosity, is proportional to the LDPE content for both series of blends investigated. Comparison of the EV of the LLDPE/LDPE blend estimated from the analysis of the flow into an orifice die to the EV value estimated from the analysis of the flow into a capillary die with a flat entry, showed that the difference in geometry had little effect on the EV estimates.     

The effect of powder particle fusion on the mechanical properties of ultra-high molecular weight polyethylene

Rheo-optical and mechanical property studies with compression molded ultra-high molecular weight polyethylene specimens at different temperatures indicate that their mechanical performance is dependent on the degree of fusion of the powder particles during compression and can be enhanced by heating the polymer powder at temperatures above 220°C. Although the mechanical performance of the compression molded specimens can be improved further by solid-state drawing at a draw ratio 5, the anisotropic morphologies from molded specimen above 220°C have higher initial slope of stress to elongation, strength to break, and an outstanding elastic recovery in compreision to the compression molded specimens at 180°C.     

The adhesive properties of chlorinated ultra-high molecular weight polyethylene

Ultra-high molecular weight polyethylene (UHMW-PE) is well known for its abrasion and chemical resistance. Recently we developed a new application for UHMW-PE as a liner in elastomeric hoses. It was found that the adhesion between UHMW-PE and elastomers such as ethylene-propylene-diene monomer (EPDM) and styrene-butadiene rubber (SBR) is sufficient for practical applications, but the adhesion to nitrile rubber (NBR) is poor. In order to improve the adhesion between NBR and the UHMW-PE liner, (nascent) powder chlorinated polyethylenes were used as interlayers between UHMW-PE and NBR. These powder chlorinated polyethylenes are polymers with a dual nature and are composed of highly chlorinated polyethylene segments compatible with NBR and polyethylene segments compatible with UHMW-PE. In order to achieve sufficient adhesion, the chlorine content of the chlorinated blocks should be at least 15 wt%. If these powder chlorinated UHMW-PEs have a chlorine content of 15 wt% in the chlorinated blocks, dilution with polyethylene hardly affects the adhesive properties, which is an advantage in the practical use of these materials as interlayers.     

Effects of additives on gel-spinning of ultra-high molecular weight polyethylene

Conclusions As judged from the fibre tensile strength-extrudate draw speed relationship for UHMWPE solutions in paraffin oil, carbon black particles diminish flow instabilities and extrudate irregularities as does EPDM rubber. Reductions in fibre tensile strength by both additives is caused by their weakening the fibre structure.Increasing the shear rate at the wall by using a more abrupt die geometry lowers drastically the mechanical properties of the fibres.     

Effects of processing conditions and copolymer molecular weight on the mechanical properties and morphology of compatibilized polymer blends

The mechanical properties and morphology of melt mixed polystyrene (PS)/polyethylene (PE) blends that were modified by the addition of up to 16% of a semicrystalline PS-b-hPB (hydrogenated polybutadiene) diblock copolymer with varying molecular weight are reported. As a result of the blocks of the copolymer penetrating the corresponding homopolymers, these diblock copolymers are capable of reinforcing the PS/PE interface significantly. This increase in interfacial strength between the immiscible blend components does not necessarily result in an improvement in the mechanical properties of the blends as measured by Izod or tensile tests. This may be because the effect of the copolymers on the rheological properties of the blends during processing outweighs their emulsifying/reinforcing effects. If found to be universally true for polymer blends, these results suggest that the relationship between the effects of copolymers on interfacial strength, their emulsifying effects, and the mechanical properties of copolymer modified blends are not as simple as suggested by many statements found in the literature.     

Role of embedded carbon particles on the morphology,microstructure and transport properties of sintered ultra-high molecular weight polyethylene

Selected ultra-high molecular weight polyethylene (UHMWPE) samples extracted from controlled positions along a representative reel from which ski bases are made were analyzed and compared to each other to test their composition and homogeneity. Scanning electron microscopy shows a UHMWPE matrix in which spherical particles are partly agglomerated and homogeneously distributed. Transmission electron microscopy, besides this, reveals the presence of a minority species, namely plate-like inclusions dispersed throughout the matrix. Raman features are traced back to structurally disordered carbonaceous material, with trigonal bond coordination. Surface electrical resistivity is quite low as compared to typical values for UHMWPE, being critically affected by the amount and spatial distribution of carbon particles. The observed homogeneity of distribution of carbon particles in the matrix is likely to be responsible for its ability to dissipate in an effective way the considerable amount of heat generated during ski gliding on hard, packed snow, thus preventing major structural damage of ski bases.     

Liquid-liquid phase separation in blends of a linear low-density polyethylene with a low-density polyethylene

A linear low-density butene copolymer, of overall branch content 3 mol %, has been blended with a low-density polyethylene. The low-density polyethylene has an overall branch content of 5 mol %, including both long and short branches. The two materials were blended in a wide range of compositions and the phase behavior investigated using indirect experimental methods, the examination of quenched blends by differential scanning calorimetry, and transmission electron microscopy. After quenching from temperatures up to 170°C, blends, of almost all compositions, show two crystal populations, separated on a micron scale. It is argued that this implies that the blends were phase separated in the melt before quenching. This behavior shows good agreement with predictions based on previous extensive studies of binary and ternary blends of linear with lightly branched polyethylenes. © 1997 John Wiley & Sons, Inc. J Appl Polym Sci 65: 1921–1931, 1997     

The effect of ultra-high molecular weight polyethylene fiber on the mechanical properties of acrylic bone cement

The effects of the addition of ultra-high molecular weight polyethylene fiber (UHMWPE) on the mechanical properties of standard surgical Simplex-P radiopaque bone cement have been investigated. It was found that the tensile strength and tensile modulus were apparently not improved by the incorporation of UHMWPE in the acrylic bone cement. The results of bending strength and bending modulus indicated that a reinforcing effect is obtained at UHMWPE contents as low as 1 wt%, and then levelled off with increasing UHMWPE contents. When the UHMWPE contents as low as 2 wt%, the values of compressive strength and modulus seemed approximate the same; whereas the values of compressive strength and modulus decreased with increasing UHMWPE contents. From the results of dynamic mechanical analysis (DMA), the values of dynamic storage modulus of bone cement increased at UHMWPE fiber as low as 2 wt%, but beyond that UHMWPE content the value of the dynamic storage modulus decreased with increasing UHMWPE contents. The same results were also found for the dynamic loss modulus. When methyl methacrylate was grafted onto UHMWPE by plasma and UV irradiation treatment, it was found that by adding the treated UHMWPE fiber in acrylic bone cement had a significant reinforcing effect on the mechanical properties of bone cement.     

Preparation of ultra-high modulus linear polyethylenes; effect of molecular weight and molecular weight distribution on drawing behaviour and mechanical properties

A systematic investigation of the effect of molecular weight and molecular weight distribution on the cold drawing behaviour of linear polyethylene has been undertaken. In the molecular weight range studied, the natural draw ratio was very sensitive to the morphology of the initial material; spectacular effects on the natural draw ratio were observed provided that an optimum initial morphology was achieved. These effects can be related to both molecular weight and molecular weight distribution.The extensional modulus and melting behaviour of the drawn material was also examined. To a first approximation the extensional modulus related to the natural draw ratio, and at very high draw ratios (～30) extremely high extensional moduli (～700kbar) were obtained. The structure and properties of the drawn material did, however, also depend on the molecular weight and molecular weight distribution. In particular, when certain molecular weight requirements were satisfied, the oriented samples showed the presence of extended chain material. It does, however, appear that although differences in molecular weight and molecular weight distribution give rise to differences in extensional moduli, the presence of extended chain crystallization per se is not a necessary requirement for the production of high modulus material.     

Effects of the processing conditions and blending with linear low-density polyethylene on the properties of low-density polyethylene films

Effects of blending low-density polyethylene (LDPE) with linear low-density polyethylene (LLDPE) were studied on extrusion blown films. The tensile strength, the tear strength, the elongation at break, as well as haze showed more or less additivity between the properties of LDPE and LLDPE except in the range of 20–40% where synergistic effects were observed. The LLDPE had higher tensile strength and elongation at break than did the LDPE in both test directions, as well as higher tear strength in the transverse direction. The impact energies of the LLDPE and the LDPE were approximately the same, but the tear strength of the LLDPE was lower than that of LDPE in the machine direction. The comparative mechanical properties strongly depend on the processing conditions and structural parameters such as the molecular weight and the molecular weight distribution of both classes of materials. The LLDPE in this study had a higher molecular weight in comparison to the LDPE of the study, as implied from its lower melt flow index (MFI) in comparison to that of the LDPE. The effects of processing conditions such as the blow-up ratio (BUR) and the draw-down ratio (DDR) were also studied at 20/80 (LLDPE/LDPE) ratio. Tensile strength, elongation at break, and tear strength in both directions became equalized, and the impact energy decreased as the BUR and the DDR approached each other.     

Thermal properties,rheology and sintering of ultra high molecular weight polyethylene and its composites with polyethylene terephthalate

The addition of polyethylene terephthalate (PET) fibers in ultra high molecular weight polyethylene (UHMWPE) may be a promising approach to achieve improved wear properties in artificial joints. Since UHMWPE/PET composites are processed by compression molding, which involves compaction and sintering of polymeric powders, this article investigates their rheology, thermal properties, and sintering behavior to aid in the identification and selection of optimum processing conditions. Isothermal crystallization kinetics studies have revealed that crystallization of UHMWPE proceeds via heterogeneous nucleation and is governed by two‐dimensional growth. The crystallization rates of the composites were lower than those of the neat material, whereas their ultimate crystallinities were higher. The UHMWPE/PET composites had higher viscosity and elasticity than the neat resin. In the presence of PET fibers the onset of sintering took place at higher temperatures but proceeded at substantially higher rates as compared with pure UHMWPE. A marked discrepancy between the Eshelby‐Frenkel model and experimental sintering data suggests that viscous flow is not the prevailing mechanism for coalescence but rather that enhanced surface area, attributed to the highly developed internal morphology of UHMWPE particles, is the controlling factor. POLYM. ENG. SCI., 45:678–686, 2005. © 2005 Society of Plastics Engineers     

Solid-state shear pulverization of post-industrial ultra-high molecular weight polyethylene: Particle morphology and molecular structure modifications toward conventional mechanical recycling

Ultra-high molecular weight polyethylene (UHMWPE) is one of the most prominent high-performance thermoplastics for biomedical, leisure, and coating applications. Large-scale recycling of UHMWPE is extremely difficult due to the high melt viscosity of the material as well as its exceptional chemical resistance and impact strength. There is a need for a commercially scalable methodology that can process the waste feedstock for mechanical recycling while sustaining the outstanding physical properties of the material. Solid-state shear pulverization (SSSP) is a continuous, twin-screw extruder-based processing technique in which the low-temperature application of shear and compressive forces impart changes in structure at different length scales to overcome the challenges of difficult-to-recycle polymers. This paper investigates the use of SSSP in mechanically recycling post-industrial scrap UHMWPE (rUHMWPE) material from a local ski and snowboard manufacturer. The SSSP-processed particles are flat, micron-scale flakes with enhanced surface area, which can sinter very quickly when compression molded. The molded rUHMWPE samples in turn exhibit enhanced ductility and toughness compared to the as-received scrap material, based on the tunable mechanochemical modification of the ethylene chains.     

Thermal and rheological properties of polyethylene blends with bimodal molecular weight distribution

Polyethylene blends with bimodal molecular weight distribution were prepared by blending a high molecular weight polyethylene and a low molecular weight polyethylene in different ratios in xylene solution. The blends and their components were characterized by the high temperature gel permeation chromatograph (GPC), different scanning calorimetry (DSC), and small amplitude oscillatory shear experiments. The results showed that the dependence of zero‐shear viscosity (η₀) on molecular weight followed a power law equation with an exponent of 3.3. The correlations between characteristic frequency (ω₀) and polydispersity index, and between dynamic cross‐point (G_x) and polydispersity index were established. The complex viscosity (η^*) at different frequencies followed the log‐additivity rule, and the Han‐plots were independent of component and temperature, which indicated that the HMW/LMW blends were miscible in the melt state. Moreover, the thermal properties were very similar to a single component system, suggesting that the blends were miscible in the crystalline state. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Effects of maleic anhydride grafted polyethylene on rheological,thermal, and mechanical properties of ultra high molecular weight polyethylene/poly(ethylene glycol) blends

Ultra‐high molecular weight polyethylene (UHMWPE) has gained considerable fame due to its excellent wear and mechanical properties, though the inferior processability has restricted its further extensive applications. In this study, a combination of UHMWPE and poly(ethylene glycol) (PEG) was considered based on the recent reports, and aiming to further exploit the potential of PEG that acts as processing aid, and also to obtain greater enhanced processability along with other properties, the effects of incorporating maleic anhydride grafted polyethylene (MAPE) was thoroughly investigated. Rheological tests revealed a further significant reduction in melt viscosity of UHMWPE/PEG blends after MAPE introduced, showing a potential of better processability, while the flexural strength and toughness of UHMWPE blends experienced a satisfying increase without any obvious compromises in other mechanical properties. A slight improvement of thermal stability in UHMWPE ternary blends along with an increase of vicat softening temperature were characterized by thermal tests, while the crystallinity of UHMWPE was diminished after the introduction of MAPE. Morphology analysis indicated that better dispersion and decreased size of PEG particles were achieved in UHMWPE matrix when MAPE was incorporated, which confirmed the improved interfacial interactions and other reinforcements obtained in UHMWPE/PEG/MAPE blends. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42701.     

High-speed gel-spinning of ultra-high molecular weight polyethylene

Summary This communication is concerned with the gel-spinning of ultrahigh molecular weight polyethylene (UHMWPE) at speeds up to 1500 m/min. It was found that 5 wt% solutions of UHMWPE in paraffin oil could be extruded through a conical die at a rate of 100 m/min. without the appearance of filament irregularities due to elastic solution fracture. These elastic turbulences occur at extrusion speeds of about 5 m/min. Without the addition of 1 wt% of Aluminium-stearate the spinline could be stretched at most to 60 m/min at 170°C but at 210°C it did not break at a speed of 1500 m/min.These high-speed gel-spinning experiments at temperatures around 200°C yielded polyethylene fibers with a tensile strength of 3.5 GPa. It was observed that drying of the as-spun fiber containing n-hexane at constant length led to excessive crazing.