The non-equilibrium phase diagrams of flow-induced crystallization and melting of polyethylene

Atomistic Simulation of Flow-Induced Microphase Separation and Crystallization of an Entangled Polyethylene Melt Undergoing Uniaxial Elongational Flow and the Role of Kuhn Segment Extension

Atomistic simulations of the linear, entangled polyethylene C₁₀₀₀H₂₀₀₂ melt undergoing steady-state and startup conditions of uniaxial elongational flow (UEF) over a wide range of flow strength were performed using a united-atom model for the atomic interactions between the methylene groups constituting the polymer macromolecules. Rheological, topological, and microstructural properties of these nonequilibrium viscoelastic materials were computed as functions of strain rate, focusing on regions of flow strength where flow-induced phase separation and flow-induced crystallization were evident. Results of the UEF simulations were compared with those of prior simulations of planar elongational flow, which revealed that uniaxial and planar flows exhibited essentially a universal behavior, although over strain rate ranges that were not completely equivalent. At intermediate flow strength, a purely configurational microphase separation was evident that manifested as a bicontinuous phase composed of regions of highly stretched molecules that enmeshed spheroidal domains of relatively coiled chains. At high flow strength, a flow-induced crystallization (FIC) occurred, producing a semicrystalline material possessing a high degree of crystallinity and primarily a monoclinic lattice structure. This FIC phase formed at a temperature (450 K) high above the quiescent melting point (≈400 K) and remained stable after cessation of flow for temperature at or below 435 K. Careful examination of the Kuhn segments constituting the polymer chains revealed that the FIC phase only formed once the Kuhn segments had become essentially fully extended under the UEF flow field. Thermodynamic properties such as the heat of fusion and heat capacity were estimated from the simulations and found to compare favorably with experimental values.

Polymer crystallization under external flow

The general aspects of polymer crystallization under external flow, i.e., flow-induced crystallization (FIC) from fundamental theoretical background to multi-scale characterization and modeling results are presented. FIC is crucial for modern polymer processing, such as blowing, casting, and injection modeling, as two-third of daily-used polymers is crystalline, and nearly all of them need to be processed before final applications. For academics, the FIC is intrinsically far from equilibrium, where the polymer crystallization behavior is different from that in quiescent conditions. The continuous investigation of crystallization contributes to a better understanding on the general non-equilibrium ordering in condensed physics. In the current review, the general theories related to polymer nucleation under flow (FIN) were summarized first as a preliminary knowledge. Various theories and models, i.e., coil-stretch transition and entropy reduction model, are briefly presented together with the modified versions. Subsequently, the multi-step ordering process of FIC is discussed in detail, including chain extension, conformational ordering, density fluctuation, and final perfection of the polymer crystalline. These achievements for a thorough understanding of the fundamental basis of FIC benefit from the development of various hyphenated rheometer, i.e., rheo-optical spectroscopy, rheo-IR, and rheo-x-ray scattering. The selected experimental results are introduced to present efforts on elucidating the multi-step and hierarchical structure transition during FIC. Then, the multi-scale modeling methods are summarized, including micro/meso scale simulation and macroscopic continuum modeling. At last, we briefly describe our personal opinions related to the future directions of this field, aiming to ultimately establish the unified theory of FIC and promote building of the more applicable models in the polymer processing.

Direct observation of long chain enrichment in flow-induced nuclei from molecular dynamics simulations of bimodal blends

Modelling of flow-induced nucleation in polymers suggest that long chains are enriched in nuclei, relative to their melt concentration. This enrichment has important consequences for the nucleation rate and mechanism, but cannot be directly observed with current experimental techniques. Instead, we ran united atom molecular dynamics simulations of bimodal polyethylene blends, comprising linear chains at a 50 : 50 mix of long (1000 carbon) and short (500-125 carbon) chains, under shear flow. We developed a method to extract the nucleus composition during a transient start-up flow. Our simulations show significant and systematic enrichment of long-chains for all nucleus sizes up to and beyond the critical nucleus. This enrichment is quantitatively predicted by the recent polySTRAND model [Read et al. Phys. Rev. Lett. 2020, 124, 147802]. The same model parameters also correctly capture the nucleus induction time in our simulations. All parameters of the model were fitted to a small subset of our data in which long chain enhancement was absent. We conclude that long-chain enrichment is central to the mechanism of flow-induced nucleation and that this enrichment must be captured to correctly predict the nucleation rate.

PolySTRAND Model of Flow-Induced Nucleation in Polymers

We develop a thermodynamic continuum-level model, polySTRAND, for flow-induced nucleation in polymers suitable for use in computational process modeling. The model's molecular origins ensure that it accounts properly for flow and nucleation dynamics of polydisperse systems and can be extended to include effects of exhaustion of highly deformed chains and nucleus roughness. It captures variations with the key processing parameters, flow rate, temperature, and molecular weight distribution. Under strong flow, long chains are over-represented within the nucleus, leading to superexponential nucleation rate growth with shear rate as seen in experiments.

The Origins of Enhanced and Retarded Crystallization in Nanocomposite Polymers

Controlling the crystallinity of hybrid polymeric systems has an important impact on their properties and is essential for developing novel functional materials. The crystallization of nanocomposite polymers with gold nanoparticles is shown to be determined by free space between nanoparticles. Results of large-scale molecular dynamics simulations reveal while crystallinity is affected by the nanoparticle size and its volume fraction, their combined effects can only be measured by interparticle free space and characteristic size of the crystals. When interparticle free space becomes smaller than the characteristic extended length of the polymer molecule, nanoparticles impede the crystallization because of the confinement effects. Based on the findings from this work, equations for critical particle size or volume fraction that lead to this confinement-induced retardation of crystallization are proposed. The findings based on these equations are demonstrated to agree with the results reported in experiments for nanocomposite systems. The results of simulations also explain the origin of a two-tier crystallization regime observed in some of the hybrid polymeric systems with planar surfaces where the crystallization is initially enhanced and then retarded by the presence of nanoparticles.

A metastable nematic precursor accelerates polyethylene oligomer crystallization as determined by atomistic simulations and self-consistent field theory

Using PYS, TraPPE, OPLS-L, and Flexible-Williams (FW) force field models, atomistic simulations at temperatures ranging from 450 K to 600 K are performed to predict the melt density ρ, the persistence length N_p, the nematic coupling constant α, and crystallization dynamics for pentacontane (C50). The coupling constant α arises from packing entropy of rodlike Kuhn segments and increases with increasing ρ and N_p. Together with a self-consistent field theory, N_p and α are then used to predict the isotropic-to-nematic (IN) transition temperature for polyethylene (PE) oligomers as a function of chain length. The nematic phase is found to be metastable since the IN transition temperature lies below the crystal melting temperatures for C50 in simulations using different force fields. Finally, isothermal simulations of crystallization for PE C50 oligomers and C1000 polymers show that crystal nucleation may be much accelerated by quenching below the IN transition temperature, where chains in the isotropic state first rapidly form nematic ordered domains, within which crystalline order then grows. We also find that the PYS, TraPPE, and FW models overpredict the melting temperature for C50 by around 50 K, while the most flexible OPLS-L model gives a melting temperature within around 10 K of the experimental value. Although giving a more accurate melting temperature, the slow crystallization kinetics of the OPLS-L model may limit its application in direct simulations of PE crystallization.

Crystal Polymorphs and Multiple Crystallization Pathways of Highly Pressurized 1-Ethyl-3-Methylimidazolium Nitrate

Crystal polymorphs and multiple crystallization pathways of a room-temperature ionic liquid (RTIL) were observed only under high pressure (HP). The RTIL was 1-ethyl-3-methylimidazolium nitrate, [C2mim][NO3]. The HP-crystal polymorphs were related to conformations of the C2mim+ cation, and the HP-crystal pathways determined by the presence or absence of the planar′ (P′) conformation of the C2mim+ cation were switched at the bifurcation pressure (PB). Above PB, modulated crystal structures derived from the HP-inherent P′ conformer. Simultaneous X-ray diffraction and differential scanning calorimetry measurements, accompanied by optical microscope observations, confirmed the normal low-temperature crystallization of [C2mim][NO3] under ambient pressure.

A Small-Angle Neutron Scattering Environment for In-Situ Observation of Chemical Processes

A new sample environment for the observation of ongoing chemical reactions is introduced for small-angle neutron scattering (SANS) experiments which enables structural changes to be followed continuously across a wide Q-range in response to changes in the chemical environment. The approach is demonstrated and validated by performing single and multiple potentiometric titrations on an aqueous anionic surfactant solution (oligo-oxyethylene alkylether carboxylic acid in D₂O) with addition times varying from 1 s to 2 h. It is shown that the continuous flow set-up offers considerable advantages over classical ‘static’ measurements with regards to sample throughput, compositional precision and the ability to observe fast structural transitions. Finally, the capabilities and ongoing optimisation of the sample environment are discussed with reference to potential applications in the fields of biology, colloidal systems and complex soft matter.

A portable extruder for in situ wide angle x-ray scattering study on multi-dimensional flow field induced crystallization of polymer

We have designed and constructed a portable extruder with a rotatable mandrel, which can be employed to study the multi-dimensional flow field (MDFF) induced crystallization of polymer combined with in situ wide angle x-ray scattering (WAXS). With the piston driving the melt sample to flow along the channel, a direct axial shear field is achieved. At the same time, the central mandrel keeps rotating under a stable speed, providing the sample with an additional circumferential shear field. By presetting different proportions of the two shear fields, namely, axial and circumferential, various flow states of the sample can be obtained, which makes it capable of investigating the effects of MDFF on polymer crystallization. We have performed an in situ WAXS experiment of MDFF induced crystallization of isotactic polypropylene based on the portable extruder at the beam line BL16B in Shanghai Synchrotron Radiation Facility. The rheological and structural information is collected simultaneously, which manifests the viability of the portable extruder on regulating MDFF and can provide guidance for polymer processing.

Rheological Link Between Polymer Melts with a High Molecular Weight Tail and Enhanced Formation of Shish-Kebabs

Presence of an ultra high molecular weight (UHMw) fraction in flowing polymer melts is known to facilitate formation of oriented crystalline structures significantly. The UHMw fraction manifests itself as a minor tail in the molar mass distribution and is hardly detectable in the canonical characterization methods. In this study, alternatively, we demonstrate how the nonlinear extensional rheology reveals to be a very sensitive characterization tool for investigating the effect of the UHMw-tail on the structural ordering mechanism. Samples containing a UHMw-tail relative to samples without, exhibit a clear increase in extensional stress that is directly correlated with the crystalline orientation of the quenched samples. Extensional rheology, particularly, in combination with linear creep measurements, thus, enables the conformational evolution of the UHMw-tail to be studied and linked to the enhanced formation of oriented structures.

Structural and morphological transitions in extension-induced crystallization of poly(1-butene) melt

Structural and morphological transitions of flow-induced crystallization (FIC) in poly(1-butene) (PB-1) melt have been studied by combining extensional rheology and in situ synchrotron radiation ultrafast wide- and small-angle X-ray scattering (WAXD/SAXS) measurements. Unexpectedly, metastable Form III is crystallized directly from the PB-1 melt by high-speed extension, which has a short lifetime of several tens of milliseconds and manifests the thermodynamic and kinetic competition among Form III, Form II and melt under flow. Relative crystallinity evolution of Form II after extension reveals a crystal melting dominated process within the observation time of 120 s even under high supercooling. This is opposite to the common case of FIC but supports the idea that flow alters the obtained crystal size and its thermodynamic stability. Additionally, a morphological transition from a flow-induced network to shish is observed by SAXS with increasing extension temperature from below to above the melting point of Form II. With above observations, we construct nonequilibrium structural and morphological diagrams of FIC in strain rate-temperature space, which may guide the industrial processing of the PB-1 material.