Weldline morphology of injection molded modified poly(phenylene‐oxide)/polyamide‐6 blends

The weldline morphology of modified‐poly(phenylene‐oxide)/polyamide‐6 blends has been investigated. A distinct contacting layer consisting of fine spherical particles was observed from the V‐notch at the surface to the center of the molded part for the low viscosity ratio blend. In contrast, such small particles were not found and a slight deformation was observed near the part's surface for the high viscosity ratio blend. The weldline morphology was found to be dominated by the deformation, the breakup, and the relaxation of the dispersed modified‐poly(phenyleneoxide) phase. The effect of injection conditions on the weldline morphology has also been investigated. The morphology of the meldline was quite complicated. Distorted multi‐layered structures were observed. It was found that those structures arise from the subsequent flow after merging of the two flow fronts. Weldlines and meldlines have been studied separately, and their formation mechanisms were found to be basically similar.     

Effect of processing conditions and reactive compatibilizer on the morphology of injection molded modified poly(phenylene oxide)/polyamide‐6 blends

The effect of injection molding conditions and reactive compatibilization on the morphology of maleic anhydryde‐modified poly(phenylene oxide)/polyamide‐6 blends was investigated. The injection flow rate primarily influenced the position of the subskin layer, and the injection temperature affected the aspect ratio of the dispersed phase. A reduction of the sue of the dispersed phase occured during the converging flow in the barrel‐to‐sprue zone. The reactive compatibilization reduced the flow induced deformation, the coalescence and the breakup of particles and improved the dispersion of the minor phase.     

Compatibilization and elastomer toughening of polyamide‐6 (PA6)/poly(phenylene ether) (PPE) blends

In the elastomer‐modified (polyamide‐6/poly(phenylene ether) (PA6/PPE) = 50/50 blends, poly(styrene‐co‐maleic anhydride) (SMA) was demonstrated to be an efficient reactive compatibilizer. The G1651 elastomer was shown to be an effective impact modifier to result in superior toughness and heat‐deflection temperature (HDT) than is the 1901X elastomer for the SMA‐compatibilized blends because G1651 particles exclusively reside within the dispersed PPE phase but 1901X particles tend to distribute in the PA6 matrix and/or along the interface. The apparent average diameter of the dispersed PPE phase is insignificantly dependent on the elastomer content in the G1651‐modified blend, whereas it increases with increase of the elastomer content in the 1901X‐modified blend. Moreover, there exists a critical elastomer content, 15 phr, for the ductile–brittle transition of the G1651‐modified SMA‐modified PA6/PPE blends. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 23–32, 1999     

Reactive processing compatibilization of direct injection molded polyamide‐6/poly(ethylene terephthalate) blends

Finely dispersed blends of polyamide 6 (PA‐6) and poly(ethylene terephthalate) (PET) were obtained by direct injection molding throughout the full composition range. The blends comprised a probably pure PA‐6 phase, and a PET phase that was apparently pure in PET‐rich blends and contained slight reacted PA‐6 amounts in PA‐6‐rich blends. This very complex morphology was characterized by the presence of dispersed particles at three levels and by a very large interface area/dispersed phase volume ratio. The linear ductility behavior was attributed to both the presence of reacted copolymers and the large interface area/dispersed volume ratio, and the synergism in both the Young's modulus and yield stress to the increased orientation of the blends related to that of the pure components. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 564–574, 2005     

Impact specific essential work of fracture of compatibilized polyamide‐6 (PA6)/poly(phenylene ether) (PPE) blends

The essential work of fracture (EWF) method has aroused great interest and has been used to characterize the fracture toughness for a range of ductile metals, polymers and composites. In the plastics industry, for purposes of practical design and ranking of candidate materials, it is important to evaluate the impact essential work of fracture at high‐rate testing of polymers and polymer blends. In this paper, the EWF method has been utilized to determine the high‐rate specific essential fracture work, w_e, for elastomer‐modified PA6/PPE/SMA (50/50/5) blends by notched Charpy tests. It is found that w_e increases with testing temperature and elastomer content for a given specimen thickness. Morphologically, there are two failure mechanisms: shear yielding and pullout of second phase dispersed particles. Shear yielding is dominant in ductile fracture, whereas particle pullout is predominant in brittle fracture.     

The vibration welding of poly(phenylene oxide)/poly(phenylene sulfide) blends

The weldability of three blends of poly(phenylene oxide) and poly(phenylene sulfide), each with a different level or type of impact modifier, is assessed through 120 and 240 Hz vibration welds. The type of impact modifier is shown to have a large effect on the strength and ductility of welds. Weld strength in these blends is shown to be sensitive to the weld frequency; higher weld strengths are attained at the higher weld frequency. In these three blends, maximum relative weld strengths of about 70%, 85%, and 87% have been demonstrated at a weld frequency of 240 Hz. The highest weld strength in each of these three blends is achieved at different weld pressures.     

Study of injection molded microcellular polyamide‐6 nanocomposites

This study aims to explore the processing benefits and property improvements of combining nanocomposites with microcellular injection molding. The microcellular nanocomposite processing was performed on an injection‐molding machine equipped with a commercially available supercritical fluid (SCF) system. The molded samples produced based on the Design of Experiments (DOE) matrices were subjected to tensile testing, impact testing, Dynamic Mechanical Analysis (DMA), and Scanning Electron Microscope (SEM) analyses. Molding conditions and nano‐clays have been found to have profound effects on the cell structures and mechanical properties of polyamide‐6 (PA‐6) base resin and nanocomposite samples. The results show that microcellular nanocomposite samples exhibit smaller cell size and uniform cell distribution as well as higher tensile strength compared to the corresponding base PA‐6 microcellular samples. Among the molding parameters studied, shot size has the most significant effect on cell size, cell density, and tensile strength. Fractographic study reveals evidence of different modes of failure and different regions of fractured structure depending on the molding conditions. Polym. Eng. Sci. 44:673–686, 2004. © 2004 Society of Plastics Engineers.     

Structural properties and impact fracture behavior of injection molded blends of liquid crystalline copolyester and modified poly(phenylene oxide)

Blends of a thermotropic liquid crystalline polymer (LCP) with modified poly (phenylene oxide) (PPO) were injection molded. The morphology, tensile properties and dynamic mechanical behavior of the blends have been studied as a function of LCP content. Furthermore, the impact performance of these blends has been investigated by the instrumented Izod and Charpy falling weight tests. The critical strain energy release rate (G_IC) of the blends were determined and the G_IC values were found to be dependent on the LCP content. The results are discussed and explained in terms of materials morphology.     

Morphology and spherulitic growth kinetics in poly(ethylene oxide)/poly(n‐butyl methacrylate) blends

Results of a study concerning the morphology and the spherulite growth rates of poly(ethylene oxide) (PEO) in binary blends with poly(n‐butyl methacrylate) (PnBMA) are reported. Microscopic observations show that blending causes the spherulite structure to become coarser and less birefringent and confirms that the spherulitic growth rates of PEO were reduced by the addition of PnBMA. X‐ray diffraction studies show no change in the unit cell dimensions and a decrease in the degree of crystallinity upon blending. Analysis of the spherulite radial growth rate data by using Lauritzen–Hoffman theory indicates that crystallization in the range of 300 to 330 K occurs solely within regime III. The calculated surface free energy of folding, σ_e, for pure PEO is 57 erg cm^?2 and decreases with increasing the content of PnBMA in the blend. Copyright © 2004 Society of Chemical Industry     

Morphology and mechanical properties of polyamide‐6/K resin blends

Mechanical properties and morphological studies of compatibilized blends of polyamide‐6 (PA‐6)/K resin grafted with maleic anhydride (K‐g‐MAH) and PA‐6/K resin/K‐g‐MAH were investigated as functions of K resin/K‐g‐MAH and dispersed phase K resin concentrations, and all the blends were prepared using twin screw extruder followed by injection molding. Scanning electron microscopy (SEM) were used to assess the fracture surface morphology and the dispersion of the K resin in PA‐6 continuous phase, the results showing extensive deformation in presence of K‐g‐MAH, whereas, uncompatibilized PA‐6/K resin blends show dislodging of K resin domains from the PA‐6 matrix. Dynamic mechanical thermal analysis (DMTA) test reveals the partially miscibility of PA‐6 with K‐g‐MAH, and differential scanning calorimetry (DSC) results further identified that the introduction of K‐g‐MAH greatly improved the miscibility between PA‐6 and K resin. The mechanical properties of PA‐6/K resin blends and K‐g‐MAH were studied through bending, tensile, and impact properties. The Izod notch impact strength of PA‐6/K‐g‐MAH blends increase with the addition of K‐g‐MAH, when the K‐g‐MAH content adds up to 20 wt %, the impact strength is as more than 6.2 times as pure PA‐6, and accompanied with small decrease in the tensile and bending strength less than 12.9% and 17.5%, respectively. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Study on morphology of compatibilized poly (vinyl chloride)/ultrafine polyamide‐6 blends by styrene–maleic anhydride

Ultrafine polyamide‐6 (UPA6) with a size of 4–8 μm was prepared via jet‐milling. Blends of poly (vinyl chloride) (PVC) and UPA6 using a reactive copolymer styrene–maleic anhydride (SMA‐18%) were prepared. The change in morphology and structure of the blends were studied using differential scanning calorimetry, scanning electron microscopy, and X‐ray diffraction. The blend behavior was also determined experimentally using dynamic mechanical analysis. Contrasted to the original PA6, the crystallinity of the UPA6 decreased, the size of its crystallites were reduced, and its melting point decreased to 175°C. In all blends, PVC formed the continuous matrix phase. SMA is miscible with PVC and tends to be dissolved in the PVC phase during the earlier stages of blending. The dissolved SMA has the opportunity to react with PA6 at the interface to form the desirable SMA‐g‐PA6 copolymer. This in situ formed SMA‐g‐PA6 graft copolymer tends to anchor along the interface to reduce the interfacial tension and results in finer phase domains. Cocrystallity existed in PVC/(UPA6/SMA) at a ratio of 82/(18/5). © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 850–854, 2005     

XPS surface studies of injection-molded poly(phenylene ether)/nylon 6,6 and poly(phenylene ether)/HIPS blends

The surface compositions of a series of poly(phenylene ether)/nylon 6,6 blends (PPE/PA), and PPE/HIPS blends, prepared by melt compounding and injection molding, have been quantitatively measured using XPS. For PPE/PA blends, the surface is dominated by the PA component for blends containing more than 25 wt % PA in the bulk. The enrichment of the PA component, which is actually the component of highest surface free energy, is rationalized in terms of the bulk morphology that consists of PPE domains in a PA continuous phase. Blends prepared by reactive extrusion processes, which form compatibilizing PPE/PA copolymers, show a decrease in surface PA enrichment with increasing copolymer content in the final blend. PPE/HIPS blends have a surface composition equal to the formulated value over the entire composition range, for both molded and solvent cast blends. The addition of 5% PVME to a 60/40 PPE/HIPS blend results in a molded surface containing 35–40 wt % PVME. © 1992 John Wiley & Sons, Inc.     

Effect of starch addition on compression‐molded poly(3‐hydroxybutyrate)/starch blends

Because of their biocompatibility and total biodegradability, poly(3‐hydroxybutyrate) (PHB) and starch have attracted attention as promising raw materials for manufacture of single‐use plastic items and biomaterials. PHB/maize starch blends with starch contents in the range of 0–50 wt % were processed in an internal mixer, and their compression‐molded films were characterized by tensile tests, X‐ray diffraction, thermogravimetric analysis, wettability measurements, and scanning electron microscopy. Water and glycerol were used as plasticizers. The results indicated that the thermal degradation behavior of the blends were similar to that of pure PHB films. All the blends showed heterogeneous morphology, wherein starch granules were dispersed in continuous PHB‐rich matrix. Despite the decrease in elongation at break and tensile strength, starch incorporation of up to 30 wt % into PHB matrix resulted in materials as hard as pure PHB films, but exhibiting less crystallinity and more hydrophilic character, which might lead to a higher biodegradation rate. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 4338–4347, 2006     

Morphology and mechanical properties of poly (phenylene sulfide)/isotactic polypropylene in situ microfibrillar blends

The morphology and mechanical properties of the in situ microfibrillar blend based on isotactic polypropylene (iPP) and poly (phenylene sulfide) (PPS) were examined. The microfibrillar PPS/iPP blend was prepared through a slit‐die extrusion, hot stretching, and water quenching process. Morphological observation indicated that the well‐defined PPS microfibrils were achieved by the method used in this study, which provided a promising method for both PPS and PP recycling. The morphology study showed that the minimum diameter of PPS phase was independent of PPS concentration. The diameter of most PPS fibrils in the microfibrillar blend was unexpectedly comparable to that of the PPS particles in the common blend at the same PPS content. The tensile strength of microfibrillar blend was higher than that of common blend, indicating the mechanical enhancement of microfibrillar processing to the PPS/iPP blend. The tensile strength of the microfibrillar blend also increased with stretching. POLYM. ENG. SCI., 45:1303–1311, 2005. © 2005 Society of Plastics Engineers     

Spatial orientation of nanoclay and crystallite in microcellular injection molded polyamide‐6 nanocomposites

Three different types of characteristic structures‐microcells, nanoclay, and crystallite lamella‐exist in injection molded polyamide‐6 microcellular nanocomposites. These structures are in completely different scales. The spatial orientation of these microscale structures crucially determines the material's bulk properties. Based on scanning electron microscopy, transmission electron microscopy, and two‐dimensional X‐ray diffractometry measurements, it was found that the nanoclay and the crystallite formed special geometric structures around the microcells and near the part skins. The nanoclay platelets lay almost parallel to the surfaces of the molded parts. Preferred orientation of the crystallites was induced by the presence of the nanoclay. A molecular‐based model is proposed to describe the structural hierarchy and correlations among the microcells, nanoclay, and crystallite lamella. From the small‐angle X‐ray scattering experiments, it was found that microcellular injection molding produces relatively smaller crystallite lamella than that of conventional injection molding, and that for both solid and microcellular neat resin parts the crystallite lamella thickness at the part skin is smaller than that at the core. Polarized optical microscopy results also indicated that the size of crystallites in the microcellular neat resin and nanocomposite parts is smaller than that in the corresponding solid parts. POLYM. ENG. SCI., 47:765–779, 2007. © 2007 Society of Plastics Engineers     

Thermally crosslinkable poly(phenylene sulfide)/poly(ether sulfone)/polymerization of monomer reactant–polyimide blends

The effects of thermally crosslinkable polymerization of monomer reactant–polyimide (POI) on the miscibility, morphology, and crystallization of partially miscible poly(ether sulfone) (PES)/poly(phenylene sulfide) (PPS) blends were investigated with differential scanning calorimetry and scanning electron microscopy. The addition of POI led to a significant reduction in the size of PPS particles, and the interfacial tension between PPS and crosslinked POI was smaller than that between PES and crosslinked POI. During melt blending, crosslinking and grafting reactions of POI with PES and PPS homopolymers were detected; however, the reaction activity of POI with PPS was much higher than that with PES. The crosslinking and grafting reactions were developed further when blends were annealed at higher temperatures. Moreover, POI was an effective nucleation agent of the crystallization of PPS, but crosslinking and grafting hindered the crystallization of PPS. The final effect of POI on the crystallinity of the PPS phase was determined by competition between the two contradictory factors. The crosslinking and grafting reactions between the two components was controlled by the dosage of POI in the blends, the premixing sequence of POI with the two components, the annealing time, and the temperature. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 2906–2914, 2002; DOI 10.1002/app.10287     

Solid state and mechanical properties of injection molded poly(ether ether ketone)/polyarylate blends

Blends of poly(ether ether ketone) (PEEK) and bisphenol-A polyarylate (PAr) were directly prepared during the plasticization step of an injection molding machine and their solid-state and mechanical behaviors were studied. Despite the fact that PEEK-rich blends were apparently miscible by differential scanning calorimetry (DSC), from the dynamic-mechanical analysis (DMTA) results all the blends were composed of (a) a crystalline PEEK phase, (b) a practically pure amorphous PEEK phase, and (c) a PAr-rich phase richer in PEEK as the PEEK content in the blends increased. Annealed blends showed a poor mechanical performance in the PAr-rich region, but the PEEK-rich blends showed additive modulus of elasticity and tensile strength, and ductility and impact strength values similar to those of the highest of the two pure components. All the as-molded low-crystalline blends presented a synergistic behavior in the modulus of elasticity, as well as, surprisingly, in ductility and impact strength in the intermediate and slightly majority PEEK compositions. The different mechanical response of the components in fine dispersed phases and in macroscopic tensile specimens may account for the observed results.     

Description of the dynamic moduli of poly(trimethylene terephthalate)/polyamide‐12 blends in molten state

Binary melt blends of two thermoplastics—poly(trimethylene terephthalate) (PTT) and polyamide‐12 (PA12)—having a large difference in zero‐shear viscosity values, were prepared in different blending ratios (PTT/PA12 90/10, 75/25, 25/75, 10/90) by means of a twin‐screw extruder. Scanning electron microscopy (SEM) confirmed droplet morphology subsequently quantified using image analysis. Dynamic rheological behavior at blending temperature (230°C) was also recorded on a parallel plate oscillatory rheometer within the linear viscoelastic range. The applicability of two emulsion models, the Palierne analysis plus the Gramespacher and Meissner model, as well as a micromechanical model, the Coran analysis, to describe the dynamic moduli of the system in different compositions was investigated and also a comparison on these models was presented. POLYM. ENG. SCI., 45:1401–1407, 2005. © 2005 Society of Plastics Engineers     

Morphology and rheological properties of silica‐filled poly(carbonate)/poly(methyl methacrylate) blends

The effect of silica nanoparticles on the morphology and the rheological properties was investigated in the immiscible polymer blend poly(carbonate)/poly(methyl methacrylate) (PC/PMMA). In the melt state, the linear viscoelastic properties of the nanocomposite showed a reduction effect of the silica nanoparticles on the mobility of one of the polymer which is related to the state of distribution of the silica nanoparticles. Hydrophilic and hydrophobic silica particles were used to study particle migration and their effects on the morphology and it was shown that the distribution of the nanoparticles depends on the balance of interactions between the surface of the particles and the polymer components. The effect on the coarsening kinetics was investigated in both hydrophilic and hydrophobic silica‐filled blends. Compared to the hydrophilic silica, a better compatibilization can be obtained by introducing the hydrophobic silica particles at the PC/PMMA interface as the solid barrier. POLYM. ENG. SCI., 55:1951–1959, 2015. © 2014 Society of Plastics Engineers     

Crystallization behavior and mechanical properties of poly(ethylene oxide)/poly(L‐lactide)/poly(vinyl acetate) blends

Poly(vinyl acetate) (PVAc) was added to the crystalline blends of poly(ethylene oxide) (PEO) and poly(L ‐lactide) (PLLA) (40/60) of higher molecular weights, whereas diblock and triblock poly(ethylene glycol)–poly(L ‐lactide) copolymers were added to the same blend of moderate molecular weights. The crystallization rate of PLLA of the blend containing PVAc was reduced, as evidenced by X‐ray diffraction measurement. A ringed spherulite morphology of PLLA was observed in the PEO/PLLA/PVAc blend, attributed to the presence of twisted lamellae, and the morphology was affected by the amount of PVAc. A steady increase in the elongation at break in the solution blend with an increase in the PVAc content was observed. The melting behavior of PLLA and PEO in the PEO/PLLA/block copolymer blends was not greatly affected by the block copolymer, and the average size of the dispersed PEO domain was not significantly changed by the block copolymer. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 3618–3626, 2001