The particle flow of polystyrene during capillary extrusion

The melt flow of emulsion polymerized polystyrene has been investigated in accordance with the particle flow concepts developed by Berens and Folt. Particles were found to be present in the extrudate up to 210°C and resins with larger particles were found to have lower viscosities. The molecular weight appears to have no significant effect on the melt viscosity above a certain molecular weight. The energy of activation for viscous flow at 190°C and at shear stress of 5 × 10⁵ dynes/cm² was found to be 29–33 kcal/mol depending on type of resin.     

Melt flow behavior in capillary extrusion of nanosized calcium carbonate‐filled poly(L‐lactic acid) biocomposites

Nanosized calcium carbonate (nano‐CaCO₃)‐filled poly‐L ‐lactide (PLLA) biocomposites were compounded by using a twin‐screw extruder. The melt flow behavior of the composites, including their entry pressure drop, melt shear flow curves, and melt shear viscosity were measured through a capillary rheometer operated at a temperature range of 170–200°C and shear rates of 50–10³ s^?1. The entry pressure drop showed a nonlinear increase with increasing shear stress and reached a minimum for the filler weight fraction of 2% owing to the “bearing effect” of the nanometer particles in the polymer matrix melt. The melt shear flow roughly followed the power law, while the effect of temperature on the melt shear viscosity was estimated by using the Arrhenius equation. Hence, adding a small amount of nano‐CaCO₃ into the PLLA could improve the melt flow behavior of the composite. POLYM. ENG. SCI., 52:1839–1844, 2012. © 2012 Society of Plastics Engineers     

Lower Newtonian viscosities of polystyrene

A falling coaxial cylinder viscometer was used to measure the melt flow behaviour of a commercial polystyrene with Mw 260,000. The shear stress region extended down to 0.6 × 10⁴ dynes/cm² and shear rates were as low as 3 × 10^?2 sec^?1 at 186°C. The shear rate-shear stress plots were linear at low shear stresses with slopes (differential viscosities) of 3.3 × 10⁵ poises at total shear less than 120 units and decreasing differential viscosity with higher total shear. The flow curves at relatively low total shear were initially dilatant and became pseudoplastic with increasing shear stress. The inflection point represents a Newtonian apparent viscosity, which agrees fairly well with literature values for polystyrenes of the same Mw. Newtonian apparent viscosity is characteristic of a point value of shear stress and shear rate and is not necessarily a plateau region. Observation of a Newtonian region with decreasing shear stress or shear rate does not prove that this flow regime persists unchanged to zero values of the experimental parameter. The existence and magnitude of the Newtonian apparent viscosity reflects shear history of the polymer as well as its constitution and molecular weight distribution.     

Rheological properties of molten poly(ethylene terephthalate)

The complete steady-state flow properties of molten poly(ethylene terephthalate) for shear stresses ≦4.14 × 10⁶ dynes/cm² were determined. A single, complete master curve had been constructed in earlier work by Gregory and Watson; the curve interrelates the shear stress, shear rate, temperature, and molecular weight (inherent viscosity) by using a temperature superposition scheme from the literature and a similar molecular weight superposition scheme. Equations in agreement with theory and with other published experimental data were derived from the master curve. Results presented here make possible the direct calculation of the melt viscosity of poly(ethylene terephthalate) at shear stresses ≦4.14 × 10⁶ dynes/cm². The effects of a unit temperature change and/or a unit change in inherent viscosity (I. V.) on the melt viscosity were determined. For poly(ethylene terephthalate) with a 0.6 I. V., a 0.0025 change in I. V. accounts for about the same change in melt viscosity as a 1°C change in temperature.     

Flow properties of ABS (acrylonitrile–butadiene–styrene) terpolymer

ABS (acrylonitrile–butadiene–styrene) terpolymer is a two-phase thermoplastic with SAN (styrene–acrylonitrile) copolymer constituting the continuous phase (matrix). The flow properties of ABS with varying molecular parameters were studied using a capillary viscometer at the shear rate range encountered in its processing. The viscosity-average molecular weights (M_v) of matrix SAN with 26% acrylonitrile content are in the range of 90,000 to 150,000, and M_v of poly-butadiene-are in the range of 150,000 to 170,000. The weight-average molecular weight of the matrix SAN is the main controlling factor for the flow properties of ABS at low shear rate, while the molecular weight distribution of the matrix SAN becomes increasingly important with the increase of shear rate. The presence of SAN grafted polybutadiene increases the melt viscosity of ABS by 40–60% over comparable free SAN copolymer and also decreases the activation energy at constant shear stress to 24–25 kcal/mole from the 33–36 kcal/mole for free SAN. The die swell of ABS and SAN can be correlated with the dynamic shear modulus G′, and the melt fracture of ABS and SAN starts at G′ equal to 3.6 × 10⁶ dynes/cm².     

Structure and properties of polyethylene produced by γ-radiation polymerization in flow system

The radiation-induced polymerization of ethylene was carried out by use of a benchscale plant with a flow-type reactor of 1 liter capacity under the following conditions: pressure, 200–400 kg/cm²; temperature, 30–90°C; irradiation intensity, 3.8 × 10⁵ rad/hr; and ethylene flow rate, 300–3000 nl/hr. The molecular weight of polymer formed was shown to decrease with increasing reaction temperature and to increase with increasing pressure. When the ethylene flow rate increases, the molecular weight decreases in the polymerization at 30–60°C, but it does not change in the polymerization at 75–90°C. Methyl group content, which is a measure of short-chain branching of the polymer, increases with increasing reaction temperature, i.e., ca. 1 CH₃/1000 CH₂ at 30°C and ca. 9 CH₃/1000 CH₂ at 90°C. Methyl content is independent of the ethylene flow rate. The changes in the melt index of polymer with reaction conditions corresponds to the change of the molecular weight. The density, crystallinity, and melting point of polymer decrease with the reaction temperature as the short-chain branching increases, and they are almost independent of ethylene flow rate and pressure.     

Shear degradation of polyisobutene

A polyisobutene of M?_w 1.98 × 10⁶, M?_w/M?_n 1.8, was extruded in an Instron capillary rheometer. Shear degradation occurred at high shear stresses, approaching melt fracture, and was more prominent at lower extrusion temperatures for tests at 60–140°C. The capillary was 2.0 in. long with a length/diameter ratio of 66.7 and a 90° entrance angle. Repetitive extrusions at constant shear rate caused a decrease in a molecular weight and a simultaneous narrowing of the molecular weight distribution. Extrudate expansion was measured after each successive capillary pass for tests at 80°C. Extrudate swelling correlated well with (M?_z+1) M?_z/M?_w, except for the two first passes, where melt fracture was pronounced. The correlation with equilibrium extrudate expansion was almost as good for (M?_z/M?_w)^3.7 (Mill's correlation) and for M?_z+1 alone. The efficiency of bond rupture is low, with the energy required to rupture 1 mole of bonds being about 200,000 kcal at 80°C.     

The degradation of polystyrene during extrusion

An investigation was made of the magnitude and mechanism of shear degradation of a narrow distribution, high molecular weight (M_w = 670,000) polystyrene. An Instron rheometer was used to perform the extrusion at temperatures from 164° to 250°C. The change in molecular weight distribution was studied by gel permeation chromatography. The maximum shear stress employed was 5.83 kg/cm². It was found that degradation could be induced at high stress at temperatures of 50°C lower than degradation of polystyrene would occur exclusively due to thermal forces. An activation energy for the degradation, calculated at constant shear rate, was +20.2 kcal/mole. The direction and magnitude of this value are consistent with degradation induced through a mechanical reduced activation for thermal degradation.     

Rheological properties of poly(trimethylene terephthalate) in capillary flow

The shear viscosity, extensional viscosity, and die swell of the PTT melt were investigated using a capillary rheometer. The results showed that the PTT melt was a typical pseudoplastic fluid exhibiting shear thinning and extensional thinning phenomena in capillary flow. There existed no melt fracture phenomenon in the PTT melt through a capillary die even though the shear rate was 20,000 s^?1. Increasing the shear rate would decrease the flow activation energy and decline the sensitivity of the shear viscosity to the melt temperature. The molecular weight had a significant influence on the flow curve. The flow behavior of the PTT melt approached that of Newtonian fluid even though the weight‐molecular weight was below 43,000 s^?1 at 260°C. The extensional viscosity decreased with the increase of the extensional stress, which became more obvious with increasing the molecular weight. The sensitiveness of the extensional viscosity to the melt temperature decreased promptly along with increasing the extensional strain rate. The die swell ratio and end effect would increase along with increasing the shear rate and with decreasing the temperature, which represented that the increase of the shear rate and the decrease of temperature would increase the extruding elasticity of the PTT melt in the capillary die. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 705–709, 2005     

Melt Flow Properties During Capillary Extrusion of Linear Low-Density Polyethylene

Abstract

The melt flow properties of a linear low-density polyethylene (LLDPE) were measured by means of a capillary rheometer under the experimental conditions of temperatures from 220° to 260°C and apparent shear rates varying from 12 to 120 s^?1. The end pressure drop (ΔP _end) was determined by employing the Bagley's plotting method. The results showed that ΔP _end increased nonlinearly with increasing shear stress. The end pressure fluctuation phenomenon was observed at lower shear stress level, and several plateau regions were generated in the end pressure drop-shear stress curves, suggesting onset of the wall-slip phenomenon during die extrusion of the resin melt. The critical shear stress with onset end pressure fluctuation phenomenon increased with a rise of temperature. Furthermore, the melt shear flow did not strictly obey the power law. The melt shear viscosity decreased nonlinearly with increasing shear stress and with a rise of temperature, whereas the dependence of the melt shear viscosity on the test temperature accorded with a formula similar to the Arrhenius expression.     

Melt fracture of polystyrene

The results of an experimental study of melt fracture using polystyrene samples of narrow and broad molecular weight distribution are presented. The weight average molecular weight (M?_w) ranged from 9.72 × 10⁴ to 1.80 × 10⁶ and the distribution breadth M?_w/M?_η from 1.06 to 9.21. The critical shear stress varies linearly with 1/M?_w, increases slightly with temperature and is independent of the distribution of molecular weights. This type of behavior is satisfactorily explained in terms of Graessley's entanglement theory.     

A model relating the elastic properties of high-density polyethylene melts to the molecular weight distribution

An earlier model relating the variation of the steady-shear melt viscosity of high-density polyethylene to the molecular weight distribution is applied toward predicting the steady-shear elastic compliance, the first normal stress difference, and relaxation spectrum as a function of shear rate from the molecular weight distribution. The model envisions the cutting off of longer relaxation times as the shear rate is raised such that at any shear rate ${\rm \dot \gamma }$ the molecular weights and their corresponding maximum relaxation times τ_m are partitioned into two classes; the relaxation times are partitioned into operative and inoperative states, depending on whether they are less than or greater than τ_c, the maximum relaxation time allowed at ${\rm \dot \gamma }$. Equations relating molecular weight and relaxation time to the steady-shear elastic compliance and viscosity are assumed valid at nonzero shear rates, except for the partitioning effect of shear rate. The shear rate dependence of the first normal stress difference and the steady-shear viscosity for polyethylene melts is successfully predicted over the range covered by the cone-and-plate viscometer. The assumed proportionality constant between τ_c and 1/${\rm \dot \gamma }$ was determined to be 1.7. Using this relation, the maximum relaxation time at 190°C for a polyethylene molecule of molecular weight M is given by τ_m = 1.4 × 10^?19 (M)^3.33. Reasonable agreement has been obtained between the experimentally determined relaxation spectrum of a polyethylene melt and that predicted from the molecular weight distribution. The agreement is best at the longest relaxation times.     

Critcal stress and recoverable shear for polymer melt fracture

The phenomenon of extrudate distortion, which is called melt fracture, was studied for polystyrene samples of narrow and broad molecular weight distribution, and commerical samples of polypropylene and linear and branched polyethylene. It was experimentally found that the shear stress at the onset of melt fracture (τ_cr) is of the order of 10⁶ dynes/cm² and independent of the distribution of molecular weights. As the weight average molecular weight increases the shear stress τ_cr decreases. For polystyrene extruded at τ_cr the recoverable shear strain, which is defined to be half the ration (first normal stress difference/shear stress), was found proportional to the factor M _zM _z+1/M _w² which represents the distrubution of molecular weights. The proportionality is expected to hold for other polymer systems. The polymer behavior at the onset of melt fracture was explained in terms of Graessley's entanglement theory and his correlation between true and Rouse shear compliance.     

The rheology of polysulfone

The viscosity-shear rate functions for polysulfone (PSF) condensates ranging from 0.4RV to 0.95RV were determined using capillary rheometry, The most probable distribution of molecular weights of these resins allowed facile comparison with the polydisperse Bueche theory for viscosity, The agreement in shape of the viscosity function with theory was good but the data were displaced by a factor of 3 to 4 to higher reduced shear rate, a fairly common occurrence for melts. The high absolute value of PSF viscosity was explained with existing empirical correlations as a combination of low critical molecular weight and strong intermolecular interactions. The temperature dependence of viscosity was found to be close to that for polystyrene in the temperature range, T_g + 90 to T_g + 190°C. The die swell, end corrections, and melt fracture characteristics were also determined. The latter was found to occur at a constant wall shear stress of about 6 × 10⁶ dynes/cm² while the die swell and end corrections were found to be small.     

Melt rheology of nanometre‐calcium‐carbonate‐filled acrylonitrile–butadiene–styrene (ABS) copolymer composites during capillary extrusion

The melt flow properties during capillary extrusion of nanometre‐calcium‐carbonate‐filled acrylonitrile–butadiene–styrene (ABS) copolymer composites were measured by using a Rosand rheometer to identify the effects of the filler content and operation conditions on the rheological behaviour of the sample melts. The experiments were conducted under the following test conditions: temperature varied from 220 to 240 °C and shear rate ranged from 10 to 10⁴ s^?1. The filler volume fractions were 0, 10, 20, 30, 40 and 50%. The results showed that the shear flow did not strictly obey the power law under the test conditions, and that the entry pressure drop (ΔP_en) and the extension stress (σ_e) in entry flow increased nonlinearly, while the melt shear viscosity (η_s) and extension viscosity (η_e) decreased with increasing the wall shear stress (τ_w) at constant test temperature. The dependence of the melt shear viscosity on the test temperature was approximately consistent with the Arrhenius expression at fixed τ_w. When τ_w was constant, η_s and η_e increased while ΔP_en and σ_e decreased with the addition of the filler volume fraction. © 2002 Society of Chemical Industry     

Effect of annealing time and molecular weight on melt memory of random ethylene 1‐butene copolymers

The effects of annealing time and molecular weight on the strong melt memory effect observed in random ethylene 1‐alkene copolymers are analyzed in a series of model ethylene 1‐butene copolymers with 2.2 mol% branches. Melt memory is associated with molten clusters of ethylene sequences from the initial crystals that remain in close proximity and are unable to diffuse quickly to the randomized melt state, thus increasing the recrystallization rate. Melt memory persists even for greater than 1000 min annealing indicating a long‐lived nature of the clusters that only fully dissolve at melt temperatures above a critical value (>160 °C). Below the critical melt temperature, molecular weight and annealing temperature have a strong influence on the slow kinetics of melt memory. For the copolymers analyzed, slow dissolution of clusters is experimentally observed only for M_w < 50 000 g mol^?1. More stable clusters that survive higher annealing temperatures display slower dissolution rates than clusters remaining at lower temperatures. The threshold crystallinity level to enable melt memory (X_c,threshold) decreases with increasing molecular weight and decreasing annealing temperature similarly to the variation of the chain diffusivity in the melt. The process leading to melt memory is thermally activated as the variation of X_c,threshold with temperature follows Arrhenius behavior with high activation energy (ca 108 kJ mol^?1) that is independent of molecular weight. © 2018 Society of Chemical Industry     

Thermal degradation of polypropylene in a capillary rheometer

Melt viscosity of a polypropylene (PP) resin was measured in a capillary rheometer between 220 and 260°C. The melt viscosity showed a power law behavior with strong shear rate dependence. The effects of temperature and shear rate on the degradation were studied in the rheometer by heating at 260 and 280°C, and extruding at shear rates up to 10000 sec ?1 . Melt flow index (MFI) of samples after shearing and heating treatment was measured to characterize the molecular weight change. An increase in MFI was found for PP sheared at high temperature. Heating for longer time also increased MFI. Increase of shear rate had a small effect on increasing MFI at 260°C but produced a larger effect at 280°C. A constant increment in MFI was observed in PP subjected to high temperature processing and was attributed to degradation due to oxygenated products.     

Melt fracture behavior of polypropylene‐type resins with narrow molecular weight distribution. I. Temperature dependence

Polypropylene (PP)‐type resins with narrow molecular weight distribution, such as PP‐type thermoplastic elastomer PER and controlled‐rheology PP (CRPP) made by peroxide degradation of high molecular weight PP, have a problem of easy generation of skin roughness at extrusion. To examine the present state, the occurrence of skin roughness in PER and CRPP at extrusion was investigated with a capillary rheometer in a shear rate range of 12–6100 s^?1 and a temperature range of 180–280°C. A homo‐PP (HPP) and a block‐PP (BPP) with usual molecular weight distributions were used for comparison. HPP and BPP with usual molecular weight distributions show smooth extrudates at low shear rates and abruptly generate severe skin roughness “elastic failure” originating at the die entrance at a higher shear rate. PER and CRPP with narrow molecular weight distributions easily generate “sharkskin” melt fracture originating at the die exit, from a shear rate nearly one decade lower than rates of elastic failure of HPP and BPP. The sharkskin becomes more severe, with increasing shear rate, and attains to the elastic failure. The critical shear rate at which sharkskin occurs increases with increasing extrusion temperature. The critical shear rate is about 20 s^?1 at 180°C and about 120 s^?1 at 280°C, which is in the range encountered by the molten resin at extrusion processing. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2111–2119, 2002     

Influence of processing parameters on the degradation of poly(L‐lactide) during extrusion

The influence of processing conditions during melt extrusion on the degradation of poly(L ‐lactide) (PLLA) has been investigated. PLLA polymer was processed by melt extrusion in a double screw extruder at 210 and 240°C. For each extrusion temperature, two screw rotation speeds, 20 and 120 rpm, were used. To investigate the influence of moisture on the thermal degradation during processing, the PLLA granules were dried at 100°C for 5 h and then either extruded directly or conditioned at 65% RH, 20°C for 24 h prior to extrusion. The results show that a decrease in molecular weight measured as number‐average (M_n) molecular weight occurs for all combinations of process parameters used. At processing temperature of 210°C, the change in molecular weight for the dry granules was shown to be dependent on the residence time (i.e., screw rotation speed) in the melt. By changing the screw rotation speed from 120 to 20 rpm at 210°C, M_n decreased from 33,600 to 30,200 g/mol. When the processing temperature was increased to 240°C, the dry granules showed an M_n of 25,600 and 13,600 g/mol when extruded at 120 and 20 rpm, respectively. M_n for the conditioned specimens extruded at 210°C was 18,400 g/mol when processed at 120 rpm and 12,300 g/mol at 20 rpm. When processed at 240°C, 20 rpm, M_n is independent of whether the granules were dry or moist prior to extrusion. It is probably due to the fact that the degradation at 240°C is so extensive that the presence of moisture in the polymer does not contribute further to the degradation process. The stress and strain at break decreased due to degradation and were dependent on the molecular weight of the samples. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 79: 2128–2135, 2001     

Melt viscosity and flow birefringence of polycarbonate

Melt viscosity and flow birefringence of bisphenol A-type polycarbonate were measured and analyzed by the application of rubber-like photoelastic theory. The melt viscosity in the Newtonian flow region increased with the molecular weight to the power of 3.4. In polycarbonate, the shear stress of the Newtonian flow region was to 10⁶ dyn/cm², whereas in PMMA it was at most 3 = 10⁵ dyn/cm². The flow birefringence δn has a linear relation with shear stress S, that is δn = 5.7 × 10^?10 S. The principal polarization difference of flow unit α₁ – α₂ was 1.62 × 10^?23 cm³, which was obtained by the application of the rubber-like elastic theory. In PMMA, it was 3.9 = 10^?25 cm³; about 1/40 of that was polycarbonate. The anisotropy of polarizability of the flow unit of polycarbonate was also about 40 times larger than that of PMMA. So the anisotropy reflected the large flow birefringence of the polycarbonate.