Orientation-induced crystallization in isotactic polypropylene melt by shear deformation

Development of orientation-induced precursor structures (nuclei) prior to crystallization in isotactic polypropylene melt under shear flow was studied by in-situ synchrotron small-angle X-ray scattering (SAXS) and rheo-optical techniques. SAXS patterns at 165°C immediately after shear (rate = 60 s⁻¹, t_s = 5 s) showed emergence of equatorial streaks due to oriented structures (microfibrils or shish) parallel to the flow direction and of meridional maxima due to growth of the oriented layer-like structures (kebabs) perpendicular to the flow. SAXS patterns at later times (t = 60 min after shear) indicated that the induced oriented structures were stable above the nominal melting point of iPP. DSC thermograms of sheared iPP samples confirmed the presence of two populations of crystalline fractions; one at 164°C (corresponding to the normal melting point) and the other at 179°C (corresponding to melting of oriented crystalline structures). Time-resolved optical micrography of sheared iPP melt (rate = 10 s⁻¹, t_s = 60 s, T = 148°C) provided further information on orientation-induced morphology at the microscopic scale. The optical micrographs showed growth of highly elongated micron size fibril structures (threads) immediately after shear and additional spherulities nucleated on the fibrils at the later stages. Results from SAXS and rheo-optical studies suggest that a stable scaffold (network) of nuclei, consisting of shear-induced microfibrillar structures along the flow direction superimposed by layered structures perpendicular to the flow direction, form in polymer melt prior to the occurance of primary crystallization. The scaffold dictates the final morphological features in polymer.