Failure mechanisms in polyolefines: The role of crazing, shear yielding and the entanglement network

Enhancing Mechanical Performance of High-Density Polyethylene at Different Environmental Conditions with Outstanding Foamability through In-Situ Rubber Nanofibrillation: Exploring the Impact of Interface Modification

In this study, we utilized in situ nanofibrillation of thermoplastic polyester ether elastomer (TPEE) within a high-density polyethylene (HDPE) matrix to enhance the rheological properties, foamability, and mechanical characteristics of the HDPE nanocomposite at both room and subzero temperatures. Due to the inherent polarity differences between these two components, TPEE is thermodynamically incompatible with the nonpolar HDPE. To address this compatibility issue, we employed a compatibilizer, styrene/ethylene-butylene/styrene copolymer-grafted maleic anhydride (SEBS-g-MA), to reduce the interfacial tension between the two blend components. In the initial step, we prepared a 10% masterbatch of HDPE/TPEE with and without the compatibilizer using a twin-screw extruder. Subsequently, we processed the 10% masterbatch further through spun bonding to create fiber-in-fiber composites. Scanning electron microscopy (SEM) analysis revealed a significant reduction in the spherical size of HDPE/TPEE particles following the inclusion of SEBS-g-MA, as well as a much smaller TPEE nanofiber size (approximately 60-70 nm for 5% TPEE). Moreover, extensional rheological testing revealed a notable enhancement in extensional rheological properties, with strain-hardening behavior being more pronounced in the compatibilized nanofibrillar composites compared to the noncompatibilized ones. SEM images of the foam structures depicted substantial improvement in the foamability of HDPE in terms of the cell size and density following the nanofibrillation process and the use of the compatibilizer. Ultimately, the in situ rubber fibrillation and enhancement of HDPE and TPEE interface using a compatibilizer led to increasing the HDPE ductility at room and subzero temperatures while maintaining its stiffness.

Entropically Toughened Robust Biodegradable Polymer Blends and Composites for Bone Tissue Engineering

Biodegradable polymers and composites are promising candidates for biomedical implants in tissue engineering. However, state-of-the-art composite scaffolds suffer from a strength-toughness dilemma due to poor interfacial adhesion and filler dispersion. In this work, we propose a facile and scalable strategy to fabricate strong and tough biocomposite scaffolds through interfacial toughening. The immiscible biopolymer matrix is compatible by the direct incorporation of a third polymer. Densely entangled polymer chains lead to massive crazes and global shear yields under tension. Weak chemical interaction and high-shear melt processing create nanoscale dispersion of nanofillers within the matrix. The resultant ternary blends and composites exhibit an 11-fold increase in toughness without compromising stiffness and strength. At 70% porosity, three-dimensional (3D)-printed composite scaffolds demonstrate high compressive properties comparable to those of cancellous bones. In vitro cell culture on the scaffolds demonstrates not only good cell viability but also effective osteogenic differentiation of human mesenchymal stem cells. Our findings present a widely applicable strategy to develop high-performance biocomposite materials for tissue regeneration.

Recent Approaches to the Plasticization of Poly(lactic Acid) (PLA) (A Review)

Poly(lactic acid) (PLA) is a polyester attracting growing interest every year in different application fields, such as packaging, cosmetics, food, medicine, etc. Despite its significant advantages, it has low elasticity that may hinder further development and a corresponding rise in volume of consumption. This review opens a discussion of basic approaches to PLA plasticization. These considerations include copolymerization and blending with flexible polymers, introducing oligomers and low-molecular additives, as well as structural modification. It was demonstrated that each approach has its advantages, such as simplicity and low cost, but with disadvantages, including complex processing and the need for additional reagents. According to the analysis of different approaches, it was concluded that the optimal option is the application of copolymers as the additives obtained via reactive mixing to PLA and its blends with other polymers.

Failure Analysis of Abnormal Cracking of the Track Circuit Reader Antenna Baffle for High-Speed Trains

The track circuit reader (TCR) is an important part of train control systems. This paper reports a failure of the TCR antenna baffle, which is used to prevent the TCR antenna from being struck by foreign objects. The designed service life of the baffle is 4.8 million kilometers, but serious cracking was found during routine maintenance after only 0.67 million kilometers of operation. In order to avoid the hidden danger brought by the incident to the safe operation of the train, it is necessary to conduct a complete failure analysis of the failed TCR antenna baffle. Therefore, a comprehensive investigation of the base material, cleaning agents, crack morphologies, etc., was carried out, and the failure environment of the antenna baffle was verified by experiment. The final results show that the environmental stress cracking is the root cause of the failed antenna baffle, and the multiple bubbles produced by the formed process of the antenna baffle are another important cause. According to the conclusions, the solutions to prevent the reoccurrence of such failures are proposed. After these solutions are adopted, the number of failed antenna baffles is greatly reduced, which fully proves the correctness of this analysis.

Environmental Stress Cracking of High-Density Polyethylene Applying Linear Elastic Fracture Mechanics

The crack propagation rate of environmental stress cracking was studied on high-density polyethylene compact tension specimens under static loading. Selected environmental liquids are distilled water, 2 wt% aqueous Arkopal N100 solution, and two model liquid mixtures, one based on solvents and one on detergents, representing stress cracking test liquids for commercial crop protection products. The different surface tensions and solubilities, which affect the energetic facilitation of void nucleation and craze development, are studied. Crack growth in surface-active media is strongly accelerated as the solvents induce plasticization, followed by strong blunting significantly retarding both crack initiation and crack propagation. The crack propagation rate for static load as a function of the stress intensity factor within all environments is found to follow the Paris–Erdogan law. Scanning electron micrographs of the fracture surface highlight more pronounced structures with both extensive degrees of plasticization and reduced crack propagation rate, addressing the distinct creep behavior of fibrils. Additionally, the limitations of linear elastic fracture mechanisms for visco-elastic polymers exposed to environmental liquids are discussed.

Stereocomplexation Reinforced High Strength Poly(L-lactide)/Nanohydroxyapatite Composites for Potential Bone Repair Applications

Composite materials composed of polylactide (PLA) and nano-hydroxyapatite (n-HA) have been recognized as excellent candidate material in bone repai The difference in hydrophilicity/hydrophobicity and poor interfacial compatibility between n-HA filler and PLA matrix leads to non-uniform dispersion of n-HA in PLA matrix and consequent poor reinforcement effect. In this study, an HA/PLA nanocomposite was designed based on the surface modification of n-HA with poly(D-lactide) (PDLA), which not only can improve the dispersion of n-HA in the poly(L-lactide) (PLLA) matrix but also could form a stereocomplex crystal with the matrix PLLA at the interface and ultimately lead to greatly enhanced mechanical performance The n-HA/PLA composites were characterized by means of scanning electron microscopy, Fourier transform infrared spectroscopy, X-Ray diffraction, thermal gravity analysis, differential scanning calorimetry, and a mechanical test; in vitro cytotoxicity of the composite material as well as its efficacy in inducing osteogenic differentiation of rat bone marrow stromal cells (rMSCs) were also evaluated. Compared with those of neat PLLA, the tensile strength, Young’s modulus, interfacial shear strength, elongation at break and crystallinity of the composites increased by 34%, 53%, 26%, 70%, and 17%, respectively. The adhesion and proliferation as well as the osteogenic differentiation of rMSCs on HA/PLA composites were clearly evidenced. Therefore, the HA/PLA composites have great potential for bone repai.

Macromolecular Insights into the Altered Mechanical Deformation Mechanisms of Non-Polyolefin Contaminated Polyolefins

Current recycling technologies rarely achieve 100% pure plastic fractions from a single polymer type. Often, sorted bales marked as containing a single polymer type in fact contain small amounts of other polymers as contaminants. Inevitably, this will affect the properties of the recycled plastic. This work focuses on understanding the changes in tensile deformation mechanism and the related mechanical properties of the four dominant types of polyolefin (PO) (linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), and polypropylene (PP)), contaminated with three different non-polyolefin (NPO) polymers (polyamide-6 (PA-6), polyethylene terephthalate (PET), and polystyrene (PS)). Under the locally elevated stress state induced by the NPO phase, the weak interfacial adhesion typically provokes decohesion. The resulting microvoids, in turn, initiate shear yielding of the PO matrix. LLDPE, due to the linear structure and intercrystalline links, is well able to maintain high ductility when contaminated. LDPE shows deformation similar to the pure material, but with decreasing ductility as the amount of NPO increases. Addition of 20 wt% PA-6, PET, and PS causes a drop in strain at break of 79%, 63%, and 84%, respectively. The typical ductile necking of the high-crystalline HDPE and PP is strongly disturbed by the NPO phase, with a transition even to full brittle failure at high NPO concentration.

Mesoporous Membrane Materials Based on Ultra-High-Molecular-Weight Polyethylene: From Synthesis to Applied Aspects

The development of new porous polymeric materials with nanoscale pore dimensions and controlled morphology presents a challenging problem of modern materials and membrane science, which should be based on scientifically justified approaches with the emphasis on ecological issues. This work offers a facile and sustainable strategy allowing preparation of porous nanostructured materials based on ultra-high-molecular-weight polyethylene (UHMWPE) via the mechanism of environmental intercrystallite crazing and their detailed characterization by diverse physicochemical methods, including SEM, TEM, AFM, liquid and gas permeability, DSC, etc. The resultant porous UHMWPE materials are characterized by high porosity (up to ~45%), pore interconnectivity, nanoscale pore dimensions (below 10 nm), high water vapor permeability [1700 g/(m² × day)] and high gas permeability (the Gurley number ~300 s), selectivity, and good mechanical properties. The applied benefits of the advanced UHMWPE mesoporous materials as efficient membranes, breathable, waterproof, and insulating materials, light-weight materials with reduced density, gas capture and storage systems, porous substrates and scaffolds are discussed.

Structure-Property Relationships of Polyamide 12 Grades Exposed to Rapid Crack Extension

Thermoplastic materials have established a reputation for long-term reliability in low-pressure gas and water distribution pipe systems. However, occasional Slow Crack Growth (SCG) and Rapid Crack Propagation (RCP) failures still occur. SCG may initiate only a small leak, but it has the potential to trigger RCP, which is much rarer but more catastrophic and destructive. RCP can create a long, straight or meandering axial crack path at speeds of up to hundreds of meters per second. It is driven by internal (residual) and external (pressure) loads and resisted by molecular and morphological characteristics of the polymer. The safe installation and operation of a pipe throughout its service lifetime therefore requires knowledge of its resistance to RCP, particularly when using new materials. In this context, the RCP resistance of five different polyamide (PA) 12 grades was investigated using the ISO 13477 Small-Scale Steady State (S4) test. Since these grades differed not only in molecular weight but also in their use of additives (impact modifiers and pigments), structure-property relationships could be deduced from S4 test results. A new method is proposed for correlating these results more efficiently to evaluate each grade using the crack arrest lengths from individual S4 test specimens.

Crazing Effect on the Bio-Based Conducting Polymer Film

The biodegradability problem of polymer waste is one of the fatal pollutFions to the environment. Enzymes play an essential role in increasing the biodegradability of polymers. In a previous study, antistatic polymer film based on poly(lactic acid) (PLA) as a matrix and polyaniline (PAni) as a conductive filler, was prepared. To solve the problem of polymer wastes pollution, a crazing technique was applied to the prepared polymer film (PLA/PAni) to enhance the action of enzymes in the biodegradation of polymer. This research studied the biodegradation test based on crazed and non-crazed PLA/PAni films by enzymes. The presence of crazes in PLA/PAni film was evaluated using an optical microscope and scanning electron microscopy (SEM). The optical microscope displayed the crazed in the lamellae form, while the SEM image revealed microcracks in the fibrils form. Meanwhile, the tensile strength of the crazed PLA/PAni film was recorded as 19.25 MPa, which is almost comparable to the original PLA/PAni film with a tensile strength of 20.02 MPa. However, the Young modulus decreased progressively from 1113 MPa for PLA/PAni to 651 MPa for crazed PLA/PAni film, while the tensile strain increased 150% after crazing. The significant decrement in the Young modulus and increment in the tensile strain was due to the craze propagation. The entanglement was reduced and the chain mobility along the polymer chain increased, thus leading to lower resistance to deformation of the polymer chain and becoming more flexible. The presence of crazes in PLA/PAni film showed a substantial change in weight loss with increasing the time of degradation. The weight loss of crazed PLA/PAni film increased to 42%, higher than that of non-crazed PLA/PAni film with only 31%. The nucleation of crazes increases the fragmentation and depolymerization of PLA/PAni film that induced microbial attack and led to higher weight loss. In conclusion, the presence of crazes in PLA/PAni film significantly improved enzymes' action, speeding up the polymer film's biodegradability.

A Morphology-Based Model to Describe the Low-Temperature Impact Behaviour of Rubber-Toughened Polypropylene

The roles of the rubber particle size, the rubber particle size distribution and the constitutive behaviour of the isotactic polypropylene matrix have been studied by combining the Lazerri–Bucknall energy criterion for cavitation with the Van der Sanden–Meier–Tervoort ligament model adapted for impact conditions. It is concluded that an optimised morphology offers great potential to achieve enhanced mechanical properties with far less rubber and hence achieve a superior stiffness/toughness/processing balance.

The Tensile Behaviour of Highly Filled High-Density Polyethylene Quaternary Composites: Weld-Line Effects, DIC Curiosities and Shifted Deformation Mechanisms

The interactive effects between additives and weld lines, which are frequent injection-moulding defects, were studied in high-density polyethylene (HDPE) and compared to weld-line-free reference samples. These materials were formulated around a D- and I-optimal experimental design, based on a quadratic Scheffé polynomial model, with up to 60 wt% calcium carbonate, masterbatched carbon black and a stabiliser package. Where reasonable and appropriate, the behaviours of the systems were modelled using statistical techniques, for a better understanding of the underlying trends. The characterisations were performed through the use of conventional tensile testing, digital image correlation (DIC) and scanning electron microscopy (SEM). A range of complex interactive effects were found during conventional tensile testing, with DIC used to better understand and explain these effects. SEM is used to better understand the failure mechanics of some of these systems through fractography, particularly regarding particle effects. A measure is introduced to quantify the deviation of the pre-yield deformation curve from the ideal elastic case. Novel analysis of DIC results is proposed, through the use of combined time-series plots and measures quantifying the extent and localisation of peak deformation. Through this, it could be found that strong shifts in the deformation mechanisms occur as a function of formulation and the presence/absence of weld lines. Primarily, changes are noted in the onset of continuous inter- and intralamellar slip and cavitation/fibrillation, seen through the onset of localised deformation and stress-whitening.

Application of short-term methods to estimate the environmental stress cracking resistance of recycled HDPE

Environmental stress cracking is a serious problem for polyethylene because it can cause failure without any visible warning due to the slow crack growth accelerated by aggressive agents. Tie molecules and entanglements are the main macromolecular characteristic increasing environmental stress cracking resistance, thus in this work mechanical and thermal properties governed by those macromolecular characteristics are determined by performing simple tests executable in the industrial laboratories for quality control on recycled high-density polyethylene. The mutual relation between the determined properties confirms their dependence on the investigated macromolecular characteristics and allows to predict in a comparative way the expected environmental stress cracking. The mechanical properties related to the environmental stress cracking resistance are the strain hardening modulus and the natural draw ratio. The strain hardening modulus is an intrinsic property that measure the disentanglement capability of the inter-lamellar links and the natural draw ratio is a highly sensitive parameter to the macromolecular network strength via the intercrystalline tie molecules. Since the measurement of these properties according to the standard ISO 18,488 requires a temperature chamber not often available in the industrial laboratories, the tensile test was performed also at room temperature and displacement rate 0.5 mm/min; a proportionality between the data obtained at different test condition emerged. The thermal property related to the environmental stress cracking resistance is the stepwise isothermal segregation ratio that state the chain fraction that generates a high rate of tie molecules responsible of environmental stress cracking resistance.

Plastic drawing response in the biaxially oriented polypropylene (BOPP) process: polymer structure and film casting effects

Processing isotactic polypropylene (iPP) from cast film into biaxially oriented polypropylene (BOPP) involves plastic drawing of a semi-crystalline morphology in the melting range of iPP, where the crystal phase is reduced and the polymer has high mobility. The literature claims that plastic drawing in general and at elevated temperatures in particular depends predominantly on the structure of the amorphous entanglement network. We investigated this aspect using laboratory-scale biaxial drawing experiments. Three iPP homopolymer types differing in chain isotacticity and molecular weight distribution were extruded into 200-μm-thick primary sheets using 10 different extrusion settings. The sheets were biaxially drawn on a laboratory stretcher at 157°C and 160°C, recording the respective stress-strain curves. These curves were evaluated according to a rubber elasticity model to obtain the network modulus, GN, of the entanglement network. The effects of iPP type, the extrusion parameters, the resulting cast film properties, and the draw temperature on GN are discussed.

Investigation of the Mechanical Properties of Parts Fabricated with Ultrasonic Micro Injection Molding Process Using Polypropylene Recycled Material

This research focuses on investigating how physical and mechanical properties of polypropylene (PP) recycled material are modified when ultrasonic micro injection molding (UMIM) technology is used to produce material specimens. Experimental characterization by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), Fourier transform infrared (FTIR) spectra, and rheology tests show that the fabricated PP samples were able to withstand up to five times recycled processing before some signs of mechanical and physical properties degradation are observed. Surprisingly, uniaxial extension tests show an increase of 3.07%, 10.97% and 27.33% for Young’s modulus, yield stress and ultimate stress values, respectively, and a slight reduction of 1.29% for the samples elongation at break when compared to the experimental data collected from virgin material samples. The improvement of these mechanical properties in the recycled samples suggests that ultrasonic microinjection produces a mechano-chemical material change.