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.     

Fourier-transform infrared study of coextrusion-drawn poly(ethylene terephthalate)

The effects of initial morphology and extrusion temperature on the orientational anisotropy and conformational changes on coextrusion drawing of poly(ethylene terephthalate) (PET) have been determined by Fourier-transform polarized infrared spectroscopy. The samples were drawn from both amorphous and semicrystalline (50%) PET at 50 and 90°C. A strong influence of coextrusion drawing temperature was observed for overall chain orientation evaluated from the dichroic ratio of the 795-cm^?1 band for the samples prepared from the amorphous state: this dependence was less prominent in samples drawn from the semicrystalline state. Under the same drawing conditions, the dichroic ratio for the 973-cm^?1 trans band for samples prepared from the amorphous state was higher than from the semicrystalline state. Furthermore, in all samples, the relative intensity of this band was almost proportional to the degree of crystallinity. In all samples, the gauche content, evaluated from the 896-cm^?1 band, decreased with increasing draw ratio. However, the dichroic ratio of this band was near unity regardless of draw ratio, initial morphology, or extrusion temperature. From these results it is considered that all gauche units in the amorphous phase are almost isotropic in the extrusion-drawn samples with overall orientation arising largely from the crystalline chains possessing totally the trans conformation (973 cm^?1) in its content. In order to evaluate the deformation mechanism of the coextrusion drawing method, the relationship between the bulk and film surface orientation is also reported.     

Solid-state coextrusion of high-density polyethylene. I. Effects of geometric factors

The solid (crystalline) state coextrusion of two high-density polyethylenes (HDPE) having weight-average molecular weights (M_w) of 59,000 and 200,000 have been studied as a function of the geometrical arrangement and the volume fraction of the components. The extrusion rate increased nonlinearly with the volume fraction of the low-M_w, component. The rate was faster when the low-M_w, component was the core rather than the sheath in the initial cylindrical concentric billet. Thus the slow extrusion rate of high-M_w HDPE alone was increased up to ten times by coextrusion with a small fraction of the low-M_w, HDPE component in its center. Generally, the deformation flow profile changed gradually from a parabolic to a W-shaped pattern as the volume fraction of the high-M_w, component increased. However, the geometric arrangement of the two different M_w components also had a pronounced effect on the deformation. The deformation patterns showed that upon coextrusion the low- and high-M_w HDPE's were extruded at the same rate and extrusion draw ratio. The geometrical arrangement had no substantial effects on the tensile modulus and strength of the extrudates; i.e., they increased linearly with volume fraction of the high-M_w HDPE.     

Solid-state coextrusion of poly(ethylene terephthalate). I. Drawing of amorphous PET

Films of uniaxially oriented poly(ethylene terephthalate) (PET), M _v = 81,000, have been drawn by solid-state coextrusion in the range 40–100°C surrounded by polyethylene. This is well below the PET melting temperature and in some cases below its glass transition temperature. Properties of the extrudates, such as degree of crystallinity, mechanical and thermal properties, were investigated as a function of coextrusion temperature and draw ratio (EDR ≤ 4.4). The results show that the percent crystallinity depends strongly on draw ratio, whereas its sensitivity to extrusion temperature is limited only to the highest draw ratio (4.4). On the other hand, Young's modulus was sensitive to both extrusion temperature and draw ratio, exhibiting a maximum at EDR = 4.4 and T_ext = 65°C. Above this temperature, moduli decrease apparently because of increased chain mobility, resulting in dissipation of chain orientation. Furthermore, changes in yield and tensile strength followed the changes in mechanical properties, suggesting that they are dominated by the same factors. The cold-crystallization temperature T_CC also revealed information about the morphological changes occurring during the extrusion drawing. For samples of EDR = 4.4, T_CC increased with extrusion temperature, suggesting again dissipation of orientation by thermal motions. On the other hand, T_CC decreases with EDR, and a ΔT_CC as high as 73°C was found. Conventional drawing of amorphous PET has been widely reported. To our knowledge this is the first time oriented PET has been prepared using the advantages of solid-state coextrusion.     

Uniaxial Draw Of Poly(aryl-ether-ether-ketone) by solid-state extrusion

Poly(aryl-ether-ether-ketone) (PEEK) films and rods have been solid-state extruded at 154 and 310°C, respectively. The crystal orientation functions, melting behavior, density, and tensile properties of the drawn PEEK films (EDR ≤ 3.7) and rods (EDR ≤ 5.5) have been measured. As extrusion draw ratio (EDR) was increased, the c-axis orientation function, melting temperature, and tensile modulus and strength increased. Moduli up to 6.5 GPa and the strengths up to 600 MPa, 3 and 6 times the values of undrawn films, respectively, were obtained for the drawn films. The thermal expansivities along (α_‖) and perpendicular (α_?) to the draw direction of PEEK rods were measured from ?40 to +10°C. As EDR was increased, α_? increased, but α_‖ decreased. At EDRs of 3.8 and 5.5, α_‖ even exhibited negative values (about ?5 × 10^?6°C^?1), probably due to reversible contraction of elongated tie-molecules.     

Morphological and structural features of heat-treated drawn polypropylene/high-density polyethylene blends

The ion etching technique has been applied to a morphological study of mechanically blended polypropylene (PP) with high-density polyethylene (HDPE). Samples blended to PP/HDPE compositions of 65/35 and 85/15 by weight were highly drawn and then heat treated for 30 min at selected temperatures up to 163°C. When these samples are carefully ion-etched several features are observed in electron micrographs, namely (i) crosshatched, and (ii) twisted or layered textured inclusions of HDPE crystals within arrays of lamellalike PP crystals situated perpendicular to the direction of drawing. X-ray diffraction measurements of the drawn samples heat treated in the range 145–163°C for 30 min shows that oriented HDPE crystallizes with b-axis orientation along the drawing direction. Supporting evidence is obtained from electron diffraction measurements. The molecular weight of the HDPE component is a major factor in the b-axis-oriented growth of HDPE crystals in PP/HDPE blends.     

Extensional flow-induced crystallization of a polyethylene melt

Measurements of flow-induced orientation and crystallization have been made on a high-density polyethylene melt (HDPE) undergoing a planar extensional flow in a four-roll mill. The HDPE was suspended as a cylindrical droplet at the flow stagnation point in a linear low density polyethylene (LLDPE) carrier phase. Deformation and crystallization of the HDPE droplet phase were monitored using video imaging in conjunction with measurement of the birefringence and dichroism to quantify the in-situ transformation kinetics. Planar deformation rates along the symmetry axis of the molten HDPE phase were on the order of 0.03 s^?1. Measurements of the initial transformation rate following flow cessation at 131.5°C and 133.2°C show a dependence on initial amorphous phase orientation and the total Hencky strain achieved during flow. The flow-induced crystallization rate is enhanced over the quiescent transformation rate by orders of magnitude, however, the dependence on temperature is less dramatic than expected for a nucleation-controlled growth mechanism. Analysis demonstrates that the melting point elevation model cannot account either qualitatively or quantitatively for the phenomena observed, suggesting that alternative explanations for the strong orientation dependence of the transformation rate are needed.     

Dry jet-wet spinning of strong cellulose filaments from ionic liquid solution

Considerable growth is expected in the production of man-made cellulose textile fibers, which are commercially produced either via derivatization to form cellulose xanthate (viscose) or via direct dissolution in N-methylmorpholine N-oxide (Lyocell). In the study at hand, cellulosic fibers are spun from a solution in the ionic liquid [DBNH] [OAc] into water, resulting in properties equal or better than Lyocell (tensile strength 37 cN tex^?1 or 550 MPa). Spinning stability is explored, and the effects of extrusion velocity, draw ratio, spinneret aspect ratio and bath temperature on mechanical properties and orientation are discussed. With the given set-up, tenacities and moduli are improved with higher draw ratios, while elongation at break, the ratio of wet to dry strength, modulus of resilience and birefringence depend little on draw ratio or extrusion velocity, elastic limit not at all. We find the process robust and simple, with stretching to a draw ratio of 5 effecting most improvement, explained by the orientation of amorphous domains along the fiber axis.     

Orientation behavior of high-modulus polyoxymethylene produced by microwave heating drawing

The orientation behavior of high-modulus polyoxymethylene tapes produced by tensile drawing with microwave heating has been investigated over the draw ratio range 10–29. Young's modulus E increases monotonically with draw ratio λ and reaches 55 GPa. The volume fraction of taut tie molecules (TTMs) in the amorphous phase has been estimated by using a Takayanagi model for oriented tapes. The increase in E at draw ratios of less than 10 is mainly due to the increase in crystalline orientation (crystalline orientation function, 0.00 → 0.99). The increase in E at draw ratios of more than 10 is due to the increase both in crystallinity (volume-fraction crystallinity, 0.84 → 0.95) and in TTM (TTM fraction, 0.14 → 0.40). The maximum Young's modulus obtainable by this method of drawing is estimated to be ca. 72 GPa from the relation between 1/E and 1/λ².     

Solvent extraction of uranium(VI) by p-tert-butylcalix[n]-arene acetate

The solvent extraction of U(VI) by p-tert-butylcalix[n]-arene acetate (H _n L) (n=4, 6, 8) has been studied. The effects of acidity in aqueous phase and concentration of extractant in organic phase on the distribution ratio were examined. It has been found that the distribution ratio is proportional to [H⁺]⁻² and [H _n L]_(O) and the extracted complex species is UO₂H _n ⁻²L. The equilibrium constants of the extraction reactions have been determined. The reaction mechanism is discussed.     

An x-ray pole figure analysis on biaxially deformed polyethylene film

The orientational states induced upon two-step biaxially stretching low-density polyethylene at 25°C have been investigated. A pole figure analysis of the (200), (020), and (002) crystalline planes has been employed to elucidate the evolution of the molecular crystalline orientation as a function of biaxial stretching. The initial uniaxial-like orientation induced along the extrusion direction of the films was gradually lost upon transverse stretching and, consequently, replaced by a biaxial orientation as suggested by the orientation functions. In these cases, the a crystallographic axis was observed to be strongly oriented along the film normal, thus confining the c and b axes to the film plane. The pole figures clearly indicate that the c and b axes are preferentially aligned 45° with respect to the stretching directions. This unique orientational state of the orthorhombic unit cell of polyethylene has been termed a biaxial-double orientation. Birefringence measurements on the biaxial samples indicated that the amorphous and crystalline regions are simultaneously biaxially oriented. The evolution of the crystalline orientation as a function of stretching was conveniently followed on a White/Spruiell orientation triangle. Quantification was hindered, however, by the presence of different crystal populations in the biaxially stretched samples. © 1994 John Wiley & Sons, Inc.     

Adhesive effect of low-density polyethylene gels on polyethylene moldings

Adhesive effect of low density polyethylene (LDPE) gels in organic solvents such as decalin, tetralin, ando-dichlorobenzene on high density polyethylene (HDPE) moldings has been investigated by shearing tests, electron microscopy, and DSC measurements. When heated at 110°C for 2 h, all of the gels showed strong adhesive strengths around 30 kg/cm², which is sufficiently strong for practical uses. It has been found that the adhesive strength increases with the heating temperature and that the temperature at which the heated gel begins to exhibit the adhesive effect depends upon solvents and is about 30° lower than that of the HDPE gels.     

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.     

Dynamic mechanical properties of extruded rods of poly(dimethylsilylene‐co‐methyl‐n‐propylsilylene)

Tractable polysilanes were prepared by the copolymerization of a methyl‐n‐propylsilylene (MP) unit into poly(dimethylsilylene), which neither dissolves in common solvents nor melts before decomposition. Although poly(dimethylsilylene‐co‐methyl‐n‐propylsilylene) has poor solubility in the composition range of the dimethylsilylene (DM) unit to the MP unit (DM/MP = 7/3 ∼ 9/1), the copolymers form the columnar mesophase at elevated temperatures. Highly oriented rods were prepared via the extrusion of the copolymers with a circular tube die in a temperature range in which the transition to the columnar mesophase began to occur (70°C when DM/MP = 7/3 and 8/2 and 120°C when DM/MP = 9/1). The extruded rods were characterized in detail by dynamic viscoelasticity and wide‐angle X‐ray diffraction (WAXD) to clarify the structure–mechanical‐property relationship. The orientation functions of the extruded rods were determined by the azimuthal intensity distribution of the WAXD reflection. The orientation function and dynamic storage modulus increased with an increasing extrusion ratio. The dynamic storage modulus at −150°C was 8 ∼ 10 GPa at the highest extrusion ratio and correlated well with the crystal orientation function. The dynamic storage modulus at room temperature was lowered by the structural relaxations at −100 ∼ +30°C, which corresponded to the molecular motion of the rigid molecular chains of the copolymer and the local molecular motion of the MP unit. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 698–706, 2000     

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.     

Epitaxial and graphoepitaxial growth of isotactic polypropylene (iPP) from the melt on highly oriented high density polyethylene (HDPE) substrates

Although under normal conditions only the crystallization behavior of PE on oriented iPP substrates can be studied due to the higher melting point of iPP, the faster crystallization rate of a molten, oriented HDPE film compared to a nonoriented iPP layer was used to study the crystallization of iPP on the oriented HDPE film by means of transmission electron microscopy (TEM) and electron diffraction (ED). Besides the known epitaxial relationship of HDPE/iPP with their chains 50° apart, two new orientation relationships with (a) chains of both polymers parallel and (hk0)_iPP in contact with the HDPE substrate, and (b) the a‐axis of iPP crystals parallel to the chain direction of HDPE but (001)_iPP in contact with the HDPE substrate were observed. Both orientations are assumed as graphoepitaxy. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 1893–1898, 1999     

Orientation-dependence of the Young's modulus of high-density polyethylene filaments

Summary TheYoungs modulus of HDPE filaments cold-drawn to different extents has been determined. The orientation distribution of the crystallites, of the total molecules and of the amorphous regions have been quantitatively determined. Using a simple one-phase model to predict theYoungs moduli, it is shown that the modulus is related primarily to the average orientation of the molecules in the amorphous regions.

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Zusammenfassung DerYoungs-Modul von HDPE-Fäden, kaltgestreckt in verschiedenem Ausmaß, wurde bestimmt. Die Orientierungsverteilung der Kristallite und der Moleküle in den amorphen Bereichen wurden quantitativ bestimmt. Unter Voraussetzung eines Einphasen-Modelles für die Berechnung derYoung-Modulen wird gezeigt, daß der Modul primär mit der mittleren Orientierung der Moleküle in den amorphen Bezirken gekoppelt ist.

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With 4 figures     

Mechanical properties of polypropylene (PP) + high‐density polyethylene (HDPE) binary blends: Non‐isothermal degradation kinetics of PP + HDPE (80/20) Blends

In this study, the mechanical properties and non‐isothermal degradation kinetics of polypropylene (PP), high‐density polyethylene (HDPE) with dilauroyl peroxide and their blends in different mixture ratios were investigated. The effects of adding dilauroyl peroxide (0–0.20 wt%) on the mechanical and thermal properties of PP + HDPE blends have been studied. On the other hand, the kinetics of the thermal degradation and thermal oxidative degradation of PP + HDPE (80/20 wt%) blends were studied in different atmospheres, to analyze their thermal stability. The kinetic and thermodynamic parameters such as the activation energy, E_a, the pre‐exponential factor, A, the reaction order, n, the entropy change, the enthalpy change, and the free energies of activated complex related to PP, HDPE, and blend systems were calculated by means of the several methods on the basis of the single heating rate. A computer program was developed for automatically processing the data to estimate the reaction parameters by using different models. Most appropriate method was determined for each decomposition step according to the least‐squares linear regression. Copyright © 2013 John Wiley & Sons, Ltd.     

Fiber spinning from the nematic melt. I. Copolyester of poly(ethylene terephthalate) and p-oxybenzoate

The Tennessee Eastman copolyester of poly(ethylene terephthalate) with 60 mol % p-oxybenzoate units was spun with various capillaries using a constant shear rate at the wall. Variables examined were the length-to-diameter ratio L/D of the capillary, the spin draw ratio V_f/V₀, and the spinning temperature. Fibers spun at 260°C showed improved homogeneity of orientation through the cross section, better crystallite orientation, and higher initial moduli as L/D was increased. The spin draw ratio required to optimize these fiber properties decreases as L/D is increased. For example, when L/D = 49.44, the initial modulus has nearly reached its plateau value at a spin draw ratio of 10. However, in contrast to the results of Sugiyama, Lewis, White, and Fellers, we find that some spin draw is always required to optimize fiber properties. Fibers spun with a spin draw ratio of approximately unity showed very poor crystallite orientation and initial moduli. It is suggested that loss of orientation under these conditions may be due to the different velocity profiles in the spinneret and in the solidifed fiber. Fibers were also spun at five temperatures using a capillary having L/D = 49.44. Shear in the capillary is more effective in introducing orientation when the spinning temperature is 260°C or above. At spinning temperatures of 240 and 250°C, the initial modulus increases more slowly with spin draw ratio, and appears to have a lower plateau value. Acierno, La Mantia, Polizzotti, Ciferri, and Valenti spun the same polymer under conditions in which essentially all the orientation was introduced by spin draw. They used a very low extrusion velocity at the spinneret, a small L/D, and spin draw ratios up to 3000. They reported that the initial modulus increased with decreasing spinning temperature, in contrast to our results. Thus the optimum spinning conditions may depend upon whether most of the orientation is introduced by shear in the capillary, or by a high spin draw ratio.     

Cutting resistance of polyethylene

A thin polyethylene strip was cut along the centerline, the legs being pulled apart to minimize friction. Fracture energy G_c was obtained from the total work expended in cutting and tearing, yielding values of 4 kJ/m² for HDPE, 2 kJ/m² for HDPE crosslinked with 2.5% dicumyl peroxide, and 1 kJ/m² for LDPE. For an oriented sample of HDPE the value was 1.5 kJ/m². These values are considerably smaller than for simple tearing, about 10 kJ/m², suggesting that plastic yielding has been reduced. However, they are much higher than expected in the absence of yielding, about 50 J/m². Values of G_c were found to be proportional to yield stress and decreased in a similar way with temperature. On comparing results for G_c with work-to-break in tension, the diameter of the plastic zone at the cut tip was inferred to be about 15–20 μm, or one to three spherulite diameters, many times larger than the blade tip radius. © 1996 John Wiley & Sons, Inc.