Influence of extrusion ratio on the thermal properties and morphology of ultradrawn high-density polyethylene

Solid-state extrusion of high-density polyethylene (HDPE) has received considerable attention. It has been shown that extrudate may have high values of optical clarity, tensile modulus (～70 GPa = 7 × 10¹¹ dyn/cm²), and c-axis orientation. The effects of extrusion conditions on the properties of the resultant fibers have, however, not yet been clarified. A systematic study has thus been made here to evaluate extrusion pressure, temperature, and extrusion (draw) ratio, and the molecular weight of extruded HDPE. The effects of extrusion ratio on the degree of crystallinity, melting behavior, crystal orientation, and dimensional change along the extrusion direction are reported.     

Solid-State coextrusion of high-density polyethylene. II. Effect of molecular weight and molecular weight distribution

The recently developed technique of solid-state coextrusion for ultradrawing semicrystalline thermoplastics has been applied in the preparation of self-reinforced high-density polyethylene extrudates. The extrudates consist of definite core and sheath phases composed of different molecular weights (M_w) in the range of 60,000–250,000 and different molecular weight distributions (M_w/M_n = 3.0–20). Concentric billets of two different phases were prepared for extrusion by in serting a polyethylene rod within a tubular billet of a different high-density polyethylene followed by melting the two phases to obtain bonding between them. The billet was then split longitudinally to increase extrusion speed and extruded at 120°C, 0.23 GPa through a conical die of extrusion draw ratio 25. Extrudates of high tensile modulus (38 GPa) and strength (0.50 GPa) could be produced in a steady state process at a rate near 0.25 cm/min. The tensile properties of the extrudates from either the single or concentric billets increased with average molecular weight and were insensitive to the molecular weight distribution of the constituent phases. Thermal analysis indicated a high deformation efficiency for the sheath and core phases of the extrudates by the coextrusion technique.     

Solid-state extrusion of chain-extended polyethylene

Billets of chain-extended polyethylene were prepared from Alathon 7050 (M_w 59,000, M_n 19,000) in an Instron capillary rheometer by crystallization at a constant pressure of 460 MPa, at a series of teimperatures from 198 to 221°C corresponding to varying degrees of undercooling. This gives chain-extended morphologies with a range of crystallinites and lamellar thicknesses. The billets were then solid-state extruded at 100°C through a conical die with 20° entrance angle up to an extrusion draw ration 23.4. Thermal behavior was studied with differential scanning calorimetry. The orientation function measured by wide-angle x-ray diffraction showed higher orientation function measured by wide-angle x-ray diffraction showed higher orientation at equivalent draw ratio when the initial billets were crystallized at lower temperatures. Drawing efficiency, defined as the ratio of molecular draw ratio (from shrinkage) to extrusion draw ratio correspondingly increases, reaching a maximum of 0.71 in our solid-state extrusion. These studies show that highly chain-extended polyethylene, i.e., with few chain entanglements, draws poorly. Drawability was improved by increasing chain entanglements by lowering the crystallization temperature. Electron micrographs of fracture surface replicas of extrudates revealed the coexistence of undeformed, tilted, partially drawn lamellae and fibrillar structure consistent with the cahange of morphologies in Peterlin's model of plastic deformation.     

Processing of semicrystalline polymers by high-stress extrusion

A study has been conducted on the solid-state extrusion of three semicrystalline polymers:poly-propylene (PP), poly(vinylidene fluoride) (PVDF), and high-density polyethylene (HDPE). HDPE has been extruded in continuous lengths with area reductions up to 25× at temperatures substantially below the melting region. Such extrusion has been identified as a solid-state process, since measurements of the temperature of the polymer during extrusion indicate the absence of significant heating due to deformation. In contrast, continuous lengths of PP and PVDF could not be obtained substantially below their melting temperatures, indicating that crystallization during extrusion is an important process for these polymers. Under severe extrusion conditions (low temperatures, high area reductions. etc.), all three polymers failed within the tapered region of the extrusion die. Two modes of failure have been identified, brittle fracture and, surprisingly, necking. Grid-line distortion patterns and a highly simplified upper-bound plasticity analysis both indicate that shear deformations are a major factor during high-stress extrusion.     

Characterization of weathered wood-plastic composite surfaces using FTIR spectroscopy, contact angle, and XPS

Much of the current growth of wood-plastic composites (WPCs) is due to increased penetration into the decking market; therefore it has become imperative to understand the durability of WPCs in outdoor applications. In this study, wood flour filled high-density polyethylene (HDPE) composites were manufactured through either injection molding or extrusion. A set of extruded composites were also planed to remove the extruded surface. Composites were weathered in a xenon-arc weathering apparatus. Scanning electron microscopy (SEM) was used to characterize the morphology of the composite surface. Attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectroscopy was useful in showing the loss of wood particles from the surface after weathering. Contact angle was higher for the extruded and planed composites compared with the injection molded composites, and was shown using X-ray photoelectron spectroscopy (XPS) to be due to lubricant used as a processing aid.     

Characteristics of solid-state extruded polyethylene

This paper describes the properties of solid-state extruded polyethylene as a function of two primary processing variables, extrusion temperature, and area reduction. The polymer was extruded in sheet form, giving a material having an orthotropic mode of orientation. Property data are presented for melting temperature and heat of fusion; sonic modulus, yield stress, and elongation at fracture; small-angle x-ray scattering; optical absorption coefficient; and morphology for material etched by ion bombardment at liquid nitrogen temperature. Combining the present results with data previously reported in the literature, it is found that over the temperature range of about 90–120°C, where polyethylene can be successfully extruded to large area reductions, many properties of the extrudates show a surprisingly small dependence on extrusion temperature. A notable exception to this behavior is the elastic modulus, which increases significantly with increasing extrusion temperatures. In contrast to extrusion temperature, area reduction is found to have a major effect on nearly all properties of solid-state extruded polyethylene. In most cases, the form of this dependence is such that the properties change rapidly at small area reductions and much more slowly at large reductions.     

Physical and mechanical properties of ultra-oriented high-density polyethylene fibers

Ultra-oriented high-density polyethylene fibers (HDPE) have been prepared by solid-state extrusion over 60–140°C range using capillary draw ratios up to 52 and extrusion pressures of 0.12 to 0.49 GPa. The properties of the fibers have been assessed by birefringence, thermal expansivity, differential scanning calorimetry, x-ray analysis, and mechanical testing. A maximum birefringence of 0.0637 ± 0.0015 was obtained, greater than the calculated value of 0.059 for the intrinsic birefringence of the orthorhombic crystal phase. The maximum modulus obtained was 70 GPa. The melting point, density, crystallinity, and negative thermal expansion coefficient parallel to the fiber axis all increase rapidly with draw ratio and at draw ratios of 20–30 attain limiting values comparable with those of a polyethylene single crystal. The properties of the fibers have been analyzed using the simple rule of mixtures, assuming a two-phase model of crystalline and noncrystalline microstructure. The orientation of the noncrystalline phase with draw ratio was determined by birefringence and x-ray measurements. Solid-state extrusion of HDPE near the ambient melting point produced a c-axis orientation of 0.996 and a noncrystalline orientation function of 0.36. Extrusion 50°C below the ambient melting point produced a decrease in crystallinity, c-axis orientation, melting point, and birefringence, but the noncrystalline orientation increased at low draw ratios and was responsible for the increased thermal shrinkage of the fibers.     

Capillary extrusion of polypropylene/high-density polyethylene immiscible blends as studied by rheo-particle image velocimetry

The capillary extrusion of polypropylene (PP) and high-density polyethylene (HDPE) immiscible blends was studied in this work by rheo-particle image velocimetry (Rheo-PIV). The PP/HDPE blends were prepared by single screw extrusion and extruded through a transparent capillary die at a temperature of 200 °C and concentrations of 80/20, 60/40, 40/60 and 20/80 wt%, respectively. PIV measurements described accurately the flow behavior of PP/HDPE blends and revealed continuous velocity profiles in the die, without macroscopic phase separation, for all the blends in the resolution range of the PIV technique. The flow behavior of all the blends was shear-thinning (power-law) type and their viscosities laid in between the values corresponding to the neat polymers and increased in an exponential way along with the concentration of the highest viscosity component in the blend (HDPE). Also, it was found that the extruded blends acquired a stratified morphology and that HDPE mitigates extrudate distortions in PP, meanwhile PP eliminates slip and flow instabilities in HDPE by migrating to the region of highest shear stresses in the die. Migration of PP to the capillary wall was corroborated by Raman spectroscopy measurements on the periphery of solid extrudates. Finally, via calculations of the density of the molten blends under flow using the velocity profiles in the die, we show that the homopolymers are compatible in the molten state and follow a simple inverse relation for their density, and an exponential one for their viscosity.     

Ultrahigh modulus polyethylene. II. Effect of drawing temperature on void formation and modulus

The maximum degree of molecular orientation and deformation obtained by ultradrawing of high-density polyethylene in air is limited by formation of internal voids (both longitudinal separation of fibrils and perpendicular cracking), and thus values of Young's moduli which are achievable by ultradrawing techniques are also limited to values much below the theoretical limit for fully extended chains. Temperature has a significant effect on the critical draw ratios at which intensive void formation begins, and also on the draw ratio at which failure occurs during the ultradrawing. The temperature effect is observed only for high-density polyethylene having a wide molecular-weight distribution, and which can be drawn at higher temperatures (30–40°C below its melting point), e.g., Dow Chemical polyethylene LP51.1. As a result of ultradrawing at higher temperatures, transparent, ultrahigh modulus samples having draw ratios of order of 40 have been obtained. The higher drawing temperatures significantly reduce fibril separation, and perpendicular cracking is shifted toward higher draw ratios. Hence, with LP51.1 the highest Young's moduli (65–70 GPa) have been exhibited by the samples which were ultradrawn at 100–105°C.     

Local process-dependent structural and mechanical properties of extrusion blow molded high-density polyethylene hollow parts

Although applied for several decades, production of hollow plastic parts by extrusion blow molding (EBM) is still over-dimensioned. To overcome this issue, a thorough investigation of the process-structure-property relationship is required. In this study, the local process-structure-property relationship for high-density polyethylene EBM containers is analyzed with differential scanning calorimetry and dynamic mechanic analysis microindentation. Local process-dependent crystallinity and complex modulus data at various processing conditions are supplemented with wide-angle X-ray diffraction and transmission electron microscopy (TEM). The crystallinities and the complex moduli clearly show lower values close to the mold side than at the inner side and the middle of the cross-section, which reflects the temperature gradient during processing. Additionally, the orientation of the polymer chain (c-axis) reveals a low level of biaxiality with a slight tendency towards transverse direction. The biaxiality increases for low mold temperature and high draw ratio. Finally, biaxiality is confirmed with TEM, which reveals no preferred lamellar orientation.     

Heating of polymers during neck propagation

The heating of polyethylene terephthalate, polyamide-66, and polyamide-6 during tensile drawing at room temperature was studied theoretically and experimentally. At a low draw rate, the necking temperature was close to the temperature of the surrounding air. An increase in the rate results in the transition to the adiabatic conditions of drawing. A necking temperature of 140°C was experimentally recorded in polyethylene terephthalate at a draw rate of 1000 mm/min and during the approach to the adiabatic conditions of drawing. A formula describing the dependence of the necking temperature on the draw rate was derived. The resulting value agreed fairly well with the theoretical estimation of the temperature. The drawing (strain) ratio in the neck and the draw stress are the crucial parameters determining the temperature. The rate of the transition to the adiabatic conditions of drawing was determined. The temperatures of adiabatic heating for various polymers were calculated. The increases in the temperatures of polycarbonate and low- and high-density polyethylene are relatively low. The increases in temperature can be regarded as moderate for polypropylene and polyvinyl chloride, while they attain the highest values in polyamide-6 and polyethylene terephthalate owing to the high draw ratios in the neck and the high draw-stress values.     

Morphology of ultradrawn polyethylene strands. II. Nitric acid etching and melting behavior

A transparent, ultraoriented, high-density polyethylene morphology has been produced by solid-state (ultradraw) extrusion in a capillary rheometer. From the perspective of modulus and nitric acid etching behavior, the uniquely high draw ratios (<325) experienced by the polyethylene during extrusion result in a morphology with a high level of chain extension. The effect of nitric acid etching on strand thermal behavior has been determined by DSC. The observed melting points of unetched strands were sensitive to the thermal contact between sample and sample pan. Under conditions ensuring improved contact, strand superheating is reduced to one-third of previously reported values. The negligible shrinkage evidenced by these strands up to 130° is consistent with the presence of a thermally stable component such as extended chain crystals or crystallized tie chains. The single, high-melting peak is gradually replaced by a nonsuperheating, lower melting peak during the initial stages of acid etch. The resultant peak melting temperature is consistent with the value predicted for the peak crystal thickness of the etched polymer. No evidence is found for a higher melting peak attributable to the extended chain crystalline component. A highly constrained morphology produced by the large tie chain content is believed responsible for strand melting behavior. The melting point of the extended chain crystalline component is reduced by defects and a large ratio of lateral to basal surface area.     

Structure of ultrathin polyethylene layers in multilayer films

The crystalline structures of “microlayer” and “nanolayer” polyethylene have been examined in coextruded films comprised of alternating layers of high-density polyethylene and polystyrene. Transmission electron microscopy (TEM), small-angle x-ray scattering (SAXS), and wide-angle x-ray scattering (WAXS) reveal that microlayer polyethylene, where the layer thickness is on the order of several microns, crystallizes with the normal unoriented lamellar morphology. In nanolayer films, where the film thickness of tens of nanometers is on the size scale of molecular dimensions, lamellae are oriented with the long axes perpendicular to the extrusion direction in a row-nucleated morphology similar to structures described in the literature. The lamellae are partially twisted about the long axes. The preferred twist angles of ±40° orient the lamellar surfaces normal to the layer surface. The row-nucleated morphology imparts highly anisotropic mechanical properties to the nanolayer polyethylene.     

Influence of the repeated extrusion on the degradation of polyethylene. Structural changes in low density polyethylene

The influence of the repeated extrusion on the molecular parameters of low density polyethylene (LDPE) Bralen NA 7-25 was studied. Virgin polyethylene was submitted up to 20 extrusion cycles and the processed samples were fractioned using precipitation fractionation. Non-fractionated samples and the individual polymer fractions were characterized by their weight average molar masses M_w (static light scattering), number average molar masses M_n (osmometry) and limiting viscosity numbers [η] (viscometry). Rheological properties in terms of shear viscosity curve, zero shear viscosity and flow activation energy were also determined by using high pressure capillary rheometer. The course of the changes in molecular parameters of LDPE is influenced both by the initial polymer structure and by the changes induced by the mechano-chemical degradation. The suggested degradation mechanisms during multiple extrusion of Bralen are chain scission predominating in the early stage of processing followed by recombination of macromolecules resulting in crosslinking and formation of microgel, which is clearly notable for the samples extruded 3-20 times.     

Relaxation processes and structure of ultradrawn polyethylene

Solid-state extruded polyethylene fibers have been prepared, with a wide range of draw ratios and constant processing temperature. The draw ratios vary from 4 up to 30, and the processing temperature was always 398 K. The extruded material behaves anisotropically, owing to the high degree of chain orientation in the drawing direction. The modulus and linear expansion coefficients in the fiber axis direction have been measured, over a wide temperature range, from 140 K up to 320 K. These two properties are closely related to the degree of structural continuity of the fibers. A fibrous structure model is proposed to explain the temperature effects and the values obtained for the modulus and expansion coefficients, in terms of crystallinity and volumetric fraction of extended-chains structure. At least three relaxation processes can be identified which cause the structural continuity of the fibers to change with temperature.     

Features of the delocalized crazing of high-density polyethylene in poly(ethylene oxide) solutions

It is shown that the deformation of high-density polyethylene films in poly(ethylene oxide) solutions occurs via the delocalized-crazing mechanism and leads to the formation of polymer blends. With an increase in the draw ratio, the concentration of poly(ethylene oxide) in the blend increases and significantly exceeds the theoretical values calculated from the polyethylene porosity and the poly(ethylene oxide) concentration in the solution. It is suggested that the high concentration of poly(ethylene oxide) in the blends is due to its adsorption on a highly developed surface of polyethylene deformed via the crazing mechanism. The composition of the resulting blends is independent of the strain rate.     

Recycling of mixed automotive plastics

Mixed plastics from junked autos were homogenized by milling or extrusion, modified by addition of low-molecular-weight low-melt-viscosity polymers, and processed by compression or injection molding. Properties were comparable with high-density polyethylene and common building panel materials.     

Confined-growth crystallization of polyethylene

A new typical orientation pattern of polyethylene has been observed in extruded, melt-drawn composites containing 10% polyethylene and 90% polystyrene. In these composites, the polyethylene phase is dispersed in the polystyrene matrix as thin, long ribbons (width 1000 Å, thickness 500 Å). The b axis of the crystallites is found oriented preferentially along the long dimension of the ribbons, i.e., in the extrusion direction. The a and c axes of the crystallites show no preferred orientation. This texture pattern is attributed to the fact that, in view of the small cross section of the polyethylene phase, crystallization can proceed only along the long axis of the ribbons. Since the b axis is the direction of fastest growth in polyethylene (and the radial direction in a spherulite), most polyethylene unit cells are oriented with their b axes in the long dimension of the ribbons.     

Formation of high-stress phase and extrusion of polyethylene due to nanoconfinements during Ziegler-Natta polymerization inside nanochannels

Polyethylene nanofibers were synthesized by heterogeneous Ziegler-Natta polymerization inside nanochannels of robust anodized aluminum oxide (AAO) membranes. The polymerization catalysts were chemisorbed at the inner wall of the nanochannels and monomers were provided through diffusion from the outside. Polyethylene is produced inside the nanochannels in the 10-20 mum region from the channel entrance. Polyethylene fibers were extruded from the nanochannels up to 3-5 mum during the polymerization. X-ray diffraction, differential scanning calorimetry, and Fourier transform infrared analyses indicated formation of a highly stressed crystalline structure although the polymerization was carried out without any external pressure or mechanical work. The highly stressed phase formation inside nanochannels and some degree of polyethylene nanofiber extrusion from nanochannels were attributed to catalytic production of excess amounts of polyethylene inside nanoconfined templates.     

Drawing of poly(p-phenylene sulfide) by solid-state coextrusion

The effects of drawing temperature on the physical and mechanical properties of poly(p-phenylene sulfide) have been studied. A melt-quenched film was drawn by solid-state coextrusion both below (75°C) and above (95 and 110°C) the glass transition temperature T_g (85°C) of PPS. The maximum extrusion draw ratio (EDR_max) increased from 3.4 to 5.6 with increasing extrusion temperature T_e from 75 to 110°C. It was found that extrusion drawing just above the T_g of PPS (95°C) produced more stress-induced crystals. A high efficiency of draw in the amorphous region was achieved by extrusion at T_e-75°C. The tensile modulus at EDR_max decreased from 5.1 to 3.5 GPa with increasing T_e from 75 to 110°C. The low efficiency of draw for the samples extruded at 110°C is explained in terms of disentanglement and chain slippage during drawing due to a less effective network.