Shear Induced Crystallization, a Relaxation Phenomenon in Polymer Melts: A Re‐Collection

Additive Manufacturing of Polyolefins

Polyolefins are semi-crystalline thermoplastic polymers known for their good mechanical properties, low production cost, and chemical resistance. They are amongst the most commonly used plastics, and many polyolefin grades are regarded as engineering polymers. The two main additive manufacturing techniques that can be used to fabricate 3D-printed parts are fused filament fabrication and selective laser sintering. Polyolefins, like polypropylene and polyethylene, can, in principle, be processed with both these techniques. However, the semi-crystalline nature of polyolefins adds complexity to the use of additive manufacturing methods compared to amorphous polymers. First, the crystallization process results in severe shrinkage upon cooling, while the processing temperature and cooling rate affect the mechanical properties and mesoscopic structure of the fabricated parts. In addition, for ultra-high-molecular weight polyolefins, limited chain diffusion is a major obstacle to achieving proper adhesion between adjunct layers. Finally, polyolefins are typically apolar polymers, which reduces the adhesion of the 3D-printed part to the substrate. Notwithstanding these difficulties, it is clear that the successful processing of polyolefins via additive manufacturing techniques would enable the fabrication of high-end engineering products with enormous design flexibility. In addition, additive manufacturing could be utilized for the increased recycling of plastics. This manuscript reviews the work that has been conducted in developing experimental protocols for the additive manufacturing of polyolefins, presenting a comparison between the different approaches with a focus on the use of polyethylene and polypropylene grades. This review is concluded with an outlook for future research to overcome the current challenges that impede the addition of polyolefins to the standard palette of materials processed through additive manufacturing.

A Review of Microinjection Moulding of Polymeric Micro Devices

Polymeric micro devices are gaining huge market potential in broad areas of medical devices, diagnostic devices, drug delivery, and optical applications. Current research is focusing on developing functional polymeric micro devices on a mass-production scale. Microinjection moulding is a promising technique suitable for fabricating polymeric micro devices. This review aims to summarise the primary achievements that have been achieved in various aspects of microinjection moulding of polymer micro devices, consisting of micro parts and micro surface structures. The relationships of the machine, process, rheology, tooling, micro/nanoscale replication, morphology, properties, and typical applications are reviewed in detail. Finally, a conclusion and challenges are highlighted.

Effect of Molar Mass on Critical Specific Work of Flow for Shear-Induced Crystal Nucleation in Poly (l-Lactic Acid)

The concept of specific work of flow has been applied for the analysis of critical shearing conditions for the formation of crystal nuclei in poly (l-lactic acid) (PLLA). Systematic variation in both time and rate of shearing the melt in a parallel-plate rheometer revealed that these parameters are interconvertible regarding the shear-induced formation of crystal nuclei; that is, low shear rate can be compensated for by increasing the shear time and vice versa. This result supports the view that critical shearing conditions can be expressed by a single quantity, providing additional options for tailoring polymer processing routes when enhanced nuclei formation is desired/unwanted. Analysis of PLLA of different mass-average molar masses of 70, 90, 120, and 576 kDa confirmed improved shear-induced crystal nucleation for materials of higher molar mass, with critical specific works of flow, above which shear-induced nuclei formation occurs, of 550, 60, 25, and 5 kPa, respectively.

Thermal Stability of Shear-Induced Precursors and Their Effect on the Crystalline Structure of β-Nucleated Isotactic Polypropylene

The thermal stability and lifetime of shear-induced precursors under various annealing temperatures, as well as the influence of their relaxation on the crystalline modification in β-nucleated isotactic polypropylene (iPP), are investigated using an ARES rheometer. The wide-angle X-ray diffraction results show that the β-crystal content of sheared β-nucleated iPP samples gradually increases with thermal treatments. The relaxation of shear-induced precursors during annealing which caused the decrease of shear nuclei may restrain the counteraction effect between the shear flow and β-nucleation agent as well as result in the increase of β-crystal content. At the early stage of relaxation, the relaxation degree is closely related to the increase of β-crystals, for which the deeper relaxed shear-induced precursors result in the more restoration of β-crystals. However, when the relaxation degree exceeded a certain limitation, where the β-crystals reached the maximum, the relaxation of shear-induced precursors will no longer influence the crystal structure of β-nucleated iPP.

A Recollection with Respect to Flow Induced Crystallization in Polymer Melt Processing

A review is given of the work in the field of flow induced crystallization in polymer melts, as has been carried out during the last twenty five years mostly in Linz. A concise discussion of some results of a recent monograph is given. In this connection polymer melt rheology provides insights into the differences of information, as provided by shear and extensional flow. These differences show up with increased degrees of deformation. One finds four important pictures in this report:

Experimental Test of Tammann's Nuclei Development Approach in Crystallization of Macromolecules

Prediction of the supermolecular structure and with that of properties of crystallizable polymers requires in-depth knowledge about the crystallization behavior, in particular the temperature-dependence of the nucleation kinetics. Typically, at low supercooling of the melt the nucleation rate/nuclei density often is assessed by optical microscopy, through an analysis of the evolution of the spherulitic superstructure. This approach fails if the nuclei density is too high, or if nuclei formation is not followed by growth due to chain-mobility constraints. In such cases, Tammann's two-stage crystal nuclei development method can be applied. It includes the formation of crystal nuclei at high supercooling of the melt, and their detection at higher temperature, after their growth to crystals. Though initially developed for analysis of low molecular mass compounds, this approach has recently also successfully been employed for analysis of the nucleation behavior of polymers, which is demonstrated here on the examples of poly (L-lactic acid) (PLLA), and poly (∊-caprolactone) (PCL). While in case of PLLA the ability to gain information about isothermal and non-isothermal nucleation is explained, in case of PCL new information about the thermal stability of nuclei is presented. The importance of such analyses in the context of understanding structure formation of polymers at processing-relevant cooling conditions is discussed.

Shear-induced enhancements of crystallization kinetics and morphological transformation for long chain branched polylactides with different branching degrees

The effects of long chain branching (LCB) degree on the shear-induced isothermal crystallization kinetics of a series of LCB polylactides (LCB PLAs) have been investigated by using rotational rheometer, polarized optical microscopy (POM) and scanning electron microscopy (SEM). Dynamic viscoelastic properties obtained by small-amplitude oscillatory shear (SAOS) tests indicate that LCB PLAs show more broadened relaxation time spectra with increasing LCB degree. Upon a pre-shear at the shear rate of 1 s⁻¹ LCB PLAs show much faster crystallization kinetics than linear PLA and the crystallization kinetics is enhanced with increasing LCB degree. By modeling the system as a suspension the quantitative evaluation of nucleation density can be derived from rheological experiments. The nucleation density is greatly enhanced with increasing LCB degree and a saturation in shear time is observed. Crystalline morphologies for LCB PLAs observed by POM and SEM demonstrate the enhancement of nucleation density with increasing LCB degree and a transformation from spherulitic to orientated crystalline morphologies. The observation can be ascribed to longer relaxation time of the longest macromolecular chains and broadened, complex relaxation behaviors due to the introduction of LCB into PLA, which is essential in stabilizing the orientated crystal nuclei after pre-shear.

Transient Cooperative Processes in Dewetting Polymer Melts

We compare the high velocity dewetting behavior, at elevated temperatures, of atactic polystyrene (aPS) and isotactic polystyrene (iPS) films, with the zero shear bulk viscosity (η_{bulk}) of aPS being approximately ten times larger than iPS. As expected, for aPS the apparent viscosity of the films (η_{f}) derived from high-shear dewetting is less than η_{bulk}, displaying a shear thinning behavior. Surprisingly, for iPS films, η_{f} is always larger than η_{bulk}, even at about 50 °C above the melting point, with η_{f}/η_{bulk} following an Arrhenius behavior. The corresponding activation energy of ∼160±10  kJ/mol for iPS films suggests a cooperative motion of segments which are aligned and agglomerated by fast dewetting.

Crystallization and dissolution of flow-induced precursors

We make use of a specially synthesized linear high density polyethylene with a bimodal molecular weight distribution (MWD) to demonstrate that it is possible to produce a suspension of extended-chain (shish) crystals only. Such a suspension can be generated at high temperatures, above but close to the equilibrium melting temperature of the unconstrained extended-chain crystals (T(m)(0)=141.2 degrees C) and requires stretch of the longest chains of the MWD. After the application of a shear flow of 120 s(-1) for 1 s at 142 degrees C, x-ray scattering suggests the presence of a large number of metastable needlelike precursors with limited or no crystallinity. Precursors that are too small dissolve on a timescale that correlates perfectly with the reptation time of the longest polymer molecules. Whereas, precursors that exceed a critical size crystallize forming extended-chain shishes.