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In-situ hybrid composites containing matrix polycarbonate, glass fiber and LCP are prepared. The morphology of LCP and the rheological behavior of the composites are described. The relationship between flowability and morphology is discussed. It is interesting to find that in some hybrid systems, composites containing more glass fiber have better flowability than composites containing less glass fiber. Glass fiber aspect ratio is an important factor that determines the flowability. Materials with short glass fiber have lower viscosities than the materials with long glass fiber. LCP morphology is another important parameter that determines the flowability of the composites. If LCP forms fibrils, the composites have better flowability. If spheres dominate the morphology of LCP, the materials have larger viscosity. The addition of glass fiber brings about new factors that influence the morphology of LCP. The LCP morphology is not only affected by LCP content, but also by glass fiber content and glass fiber length. LCP fibrils are promoted in some in-situ hybrid composites. A model is proposed to describe how fibrillation of LCP is promoted due to the addition of glass fiber.

Particle size distribution strongly affects physical and mechanical properties of filled polymers. A new model has been developed to predict agglomerate size distribution in a twin-screw extruder (TSE). The model considers the break-up and erosion processes and it uses agglomerate size population balance in its mathematical formulation. The model parameters were evaluated in simple field flow. This paper shows the validation of the model along the extruder using different screw configurations of a short twin screw extruder. Flow parameters along of the TSE necessaries to apply the new dispersion model have been calculated with ©Ludovic software. Calcium carbonate filled polypropylene system was used as model compound. The agglomerate size distribution was evaluated from micrographs of polished samples at different locations along the extruder obtained by reflected light microscopy in conjunction with-semiautomatic image analysis.

This paper is a technical report about the structure and the rheological behaviour of processed polypropylene-glass fibre composites. The present studies has been carried out as a part of the international project on the Characterization of Finite Length Composites initiated and organized by the IUPAC Working Party: Structure and Properties of Commercial Polymers. Seven industrial and university laboratories in Europe and in USA worked together in a common project to investigate the influence of the processing conditions on the rheology and manufacturing behaviour of polymer-glass composites preprocessed in a twin screw extruder. All investigations presented concern the influence of the processing procedure on the structure of the composites such as fiber length destribution, fiber orientation, destribution of the fibre concentration in the sample and the rheology of the composites. The flow behaviour dependent on the processing conditions has been measured using capillary rheometers to investigate the viscosity functions, the entrance and outlet pressures losses as well as for observations of the shape and internal structure of extruded composites. Torsional rheometers for low shear rate, oscillatory and transient viscosity behaviour and for the quantification of fibre orientation with ongoing shear process. Additionaly queeze flow experiments are made. Most laboratories used analogous recording sytems to documente the primary experimental results. So results are partially given here as direct copies from the original data readings. The different data handling and the transfer of data from laboratory to laboratory for comparison of results leads sometimes to unavoidable inhomogeneous (due to the style and possibilities of the different laboratories) presentation of the results. The present report is a result of data collecting, data comparison and documentation of results over a period of nearly ten years.

Natural fibre reinforced thermoplastics are usually processed in twin screw extruders. The present work studies the single screw extrusion process for different systems of natural fibre reinforced thermoplastics. For this study different polymer-fibre systems have been characterised in terms of the material properties that are relevant to the processing behaviour of these materials. The extrusion process has been investigated using an open-barrel single screw extruder. This equipment can be stopped at any point in operation, cooled down and opened in order to study the material transport processes that take place inside the extruder. The polymer matrices used in this study have been mainly polyethylene and polypropylene (with MFIs varying from 0.3 to 4). Fibres including jute, sisal, and cabuya have been used as discrete reinforcements of a length of 5 to 10 mm. The experiments presented here study the transport processes during single screw extrusion with special emphasis on the bubble formation mechanisms. The bubble formation process has been studied in terms of the variation in the initial fibre dispersion at the entrance of the feeding zone of the extruder. A relationship between solids conveying, plastication and bubble formation has been proposed considering the different typical cases occurring in the single screw extrusion of NFRTPs. The use of coupling and dispersion agents has been studied in terms of its relationship to bubble formation and to the final quality of the extrudates produced. Finally, morphological characterisation techniques have been adapted to understand the structure-property relationships in these materials during the extrusion process.

A non-contact method to determine the force tension of the spinning line is proposed by a non-vertical arrangement of the melt spinning equipment. The curvature of the spinline caused by gravitation was determined experimentally by measuring the spinline location. This is the key for the calculation of the filament force only by geometric measurements.

Poly (ethylene terephthalate) (PET) fiber was heated by carbon dioxide laser radiation in the continuous drawing process. By this procedure, the position of the deformation region could be fixed precisely in the air. The location of neck-like deformation fluctuated within a range of about 0.2 mm for draw ratios of 4.0 to 4.5 and within a range of about 0.5 mm for draw ratios of 5.5 to 6.0, but the location fluctuated over a range of 1.0 mm for a draw ratio of 5.0. Fiber diameter profiles, which were used to calculate Hencky strain rate profiles and apparent elongational viscosity profiles, were obtained from high-speed video camera images of the deformation region. Regardless of draw ratio, apparent elongational viscosity exhibited almost the same minimum value. Apparent elongational viscosity is much lower than the value obtained by measurement at a low, constant strain rate, but the elongational stress acting at the point where apparent elongational viscosity begins to increase steeply (Hencky strain of about 1.0) is of the same order of magnitude as the reported value. For draw ratios less than 5.0, the temperature where apparent viscosity is lowest is about 100 to 120°C, which corresponds to the flow temperature of amorphous PET, whereas for draw ratios exceeding 5.0 the temperature where apparent viscosity is lowest is about 80°C, which corresponds to the glass transition temperature. Thus, the former corresponds to so-called neck-like deformation typically observed in high-speed spinning, and the latter corresponds to necking typically observed in cold drawing. These two types of deformation appear in turns for a draw ratio of 5.0, and therefore the location of the deformation region fluctuates greatly. This measurement system can be used as a high-strain-rate elongational rheometer for analyzing practical polymer processing systems, which can easily measure the precise on-line deformation history with a time resolution in the μs level.

Stress-induced crystallization is studied in an extensional flow device (a cross-slot flow cell) for an isotactic Polypropylene (iPP) by measuring the micro-structure that develops after flow. Birefringence and Wide Angle X-ray experiments were performed. The birefringence experiments with flow below the melting temperature showed the occurrence of a fiber-like structure around the outflow centerline and, later in time, of ‘streamlines’. The latter are explained by the influence of shear gradients close to the optical windows. The WAXS experiments also showed the fiber-like structure around the outflow centerline, having orientations in the (110), (040) and (130) reflections, with a width of about 80 μm. This dominance of the elongational flow around the stagnation line could not be observed in experiments with flow above and subsequent crystallization below the melting temperature. Structure development in this cell was numerically predicted using the Leonov and the extended Pompom (XPP) model. The oriented structures can be predicted. Moreover, process conditions are found with less influence of the (unwanted) shear gradients. Finally, it was concluded that the strain hardening behavior in the Leonov model over-estimates the first component of the Finger tensor, and thus the number of flow-induced nuclei. Therefore it is recommended to use the extended Pompom model as a more realistic basis for a quantitative flow-induced crystallization model.

Melt spinning is a polymer processing technique that is strongly influenced by the extensional flow behaviour of polymer melts. Therefore only a few polymeric materials are usable for this kind of processing with sufficient take-up speeds. When approaching critical conditions of deformation most polymers show either fibre break in the molten state either by a brittle cohesive rupture or a ductile failure. During the melt spinning of pure and modified metallocene poylethylenes additional flow instabilities occur within the spinning die. Namely, wall slip, ‘sharkskin’ and pressure oscillations (gross fracture) may be obtained dependending on the volume flow rate. Pressure oscillations lead to diameter oscillations of the melt extrudate, which create local increase of tensile stress in the spin line. This effect immediately causes fiber break in the spinline. Therefore, melt spinning of polyethylenes was only possible up to a critical molecular weight or its relating melt viscosity. The limitation of the molecular weight restricts the mechanical properties of the melt spun fibres. This paper reports on an attempt to find out appropriate processing aids for suppressing ‘sharkskin’ effects and pressure oscillations in an attempt to overcome the limitation of a critical molecular weight. At first, the critical conditions for the onset of flow instabilities for higher molecular weight polymers were analysed. Further experiments concerned with the use of processing aids for melt spinning of metallocene polyethylenes of higher molecular weights. A combination of boron nitride powder and a fluoroelastomer was found to be an effective processing aid for this process.

After some general introductory remarks to the advantageous application of a twin screw extrusion to the melt spinning the lecture deals with investigations of elastomeric fibers consisting of ethylene-octene-copolymers which have been grafted by organosilanes and additionally blended with polybutylenter-ephthalates (PBT) and/or polyesterelastomers (PEE), all by means of a reactive twin screw extruder coupled with a side feeding single screw extruder in an online melt spinning process. It will be demonstrated that considerably improved mechanical properties of the elastomeric EO-fibers can be reached with this additional blend step. All spun fiber samples will be characterized regarding their structural and mechanical properties extensively. This work is a decisive expansion of our results published during the last two years regarding to the twin screw extrusion melt spinning [1 to 4].

An important problem arising in the cast film process is the so-called neck-in phenomenon, which may induce a drastic film width reduction as well as an inhomogeneous film thickness distribution (with the so called “dog-bone” defect on each side of the film). This neck-in phenomenon is highly influenced by the polymer rheology (increasing polymer elasticity leads to decrease markedly the neck-in), the stretching distance, the cooling conditions and the draw ratio. In this paper, we present a 2D Newtonian non-isothermal model based on a membrane approximation for the film. Stress balance, mass balance and temperature balance equations are solved iteratively using various finite element methods adapted to free surface problems and to transport equations. Coupling between mechanical and thermal equations is achieved introducing an Arrhenius temperature dependance for the viscosity. The influence of the heat transfer coefficient has been carefully investigated.

Polymer sintering plays a major role in processes such as rotational molding, governing the heating cycle and the properties of the final parts. There is evidence to suggest that the material molecular structure, molecular order and morphology are of importance in the sintering process. To date, however, there has been no satisfactory explanation as for their role in polymer sintering. One objective of this work is to examine the sintering behavior of ethylene copolymers under conditions related to the rotational molding process and to determine the relative effects of the polymer molecular structure and morphology on the sintering process. Sintering experiments were conducted under isothermal and non-isothermal conditions using both powder and cylindrical particles. It was found that the trends observed for the sintering of powder were consistent with the predictions of Newtonian sintering models. Sintering results obtained using cylindrical particles, however, showed significant differences not seen when using powder particles. These were attributed to the differences in the surface area between the two types of particles. It is speculated that the effect of material properties other than viscosity and elasticity are enhanced when cylindrical particles are used.

A condensed presentation of some results of a geometric character, concerning the injection molding of plastics, is given here. The author has derived these results from mathematical arguments and some simplifying assumptions, besides the usual Hele-Shaw flow conditions. The presentation here is intended for readers with an interest in polymer processing, rather than mathematics, so that the mathematical derivations are omitted in some cases, and sketchy in other cases. Instead we try to explain the results using figures, intuitive arguments and a few inevitable formulas. Since the experimental verification of the results is still very incomplete, we prefer to present them as proposed principles. Comments and suggestions for improvement are very welcome.

Sandwich injection moulding offers the possibility of combining materials with different properties and, for instance, hide a recycled constituent within a virgin ditto. This attractive potential puts great demands on the manufacturing and therefore also on the process modelling. In particular the effect on the final stress state and the deformation of the part due to the heterogeneity of the material must be clarified. This topic is addressed in this study. To start with it is confirmed that expressions for the temperature field can be much simplified without major loss of accuracy in the solution. This enables us to take an analytical approach to the modelling and the resulting equations can be solved on a spread-sheet or with a simple code. It is also shown that the derived models compare well to experiments made with a two-layered structure, indicating that the models presented can be used to estimate changes of processing conditions or material properties for sandwich structures.