Crystallization of polymer melts under fast cooling. II. High-purity iPP

Low Temperature Powder Bed Fusion of Polymers by Means of Fractal Quasi-Simultaneous Exposure Strategies

Powder Bed Fusion of Polymers (PBF-LB/P) is a layer-wise additive manufacturing process that predominantly relies on the quasi-isothermal processing of semi-crystalline polymers, inherently limiting the spectrum of polymers suitable for quasi-isothermal PBF. Within the present paper, a novel approach for extending the isothermal processing window towards significantly lower temperatures by applying the quasi-simultaneous laser-based exposure of fractal scan paths is proposed. The proposed approach is based on the temporal and spatial discretization of the melting and subsequent crystallization of semi-crystalline thermoplastics, hence allowing for the mesoscale compensation of crystallization shrinkage of distinct segments. Using thermographic monitoring, a homogenous temperature increase of discrete exposed sub-segments, limited thermal interference of distinct segments, and the resulting avoidance of curling and warping can be observed. Manufactured parts exhibit a dense and lamellar part morphology with a nano-scale semi-crystalline structure. The presented approach represents a novel methodology that allows for significantly reducing energy consumption, process preparation times and temperature-induced material aging in PBF-LB/P while representing the foundation for the processing of novel, thermo-sensitive material systems in PBF-LB/P.

Crystallization of Isotactic Polypropylene Nanocomposites with Fibrillated Poly(tetrafluoroethylene) under Elevated Pressure

Nanocomposites of isotactic polypropylene with 1–5 wt.% of fibrillated PTFE (PP/T) were prepared, and their crystallization during cooling under elevated pressure, in a wide pressure range, up to 300 MPa, as well as the resulting structure, were examined. The crystallization peak temperatures of PP/T, especially with 3 and 5 wt.% of PTFE, exceeded by up to 13 °C those of neat PP. Moreover, a fine-grain structure was formed in PP/T in the entire pressure range, which proved the ability of the fibrillated PTFE to nucleate crystallization of PP in the γ-form under elevated pressure. This also resulted in a higher crystallinity level developed in the γ-domain, before the temperature range of the α-domain was reached during cooling. Hence, the γ-content increased in comparison to that in neat PP, under the pressure up to 200 MPa, especially under 50–100 MPa.

Detection and characterization of folded-chain clusters in the structured melt of isotactic polypropyl-ene

Despite ceaseless efforts in past decades, the memory effect of semi-crystalline polymers has not been elucidated completely yet. An important reason why is that residual lamellar crystals in the structured melt are difficult to characterize. Recently, we developed a new small-angle X-ray scattering (SAXS) theory [Li et al. (2019). IUCrJ, 6, 968-983] and Fourier transform method [Li et al. (2020). CrystEngComm, 22, 3042-3058] for lamellar crystals that could derive structural information from SAXS readily. In this study, we tried to employ the new theory and method to characterize residual lamellar crystals in the structured melt. It was found that although scattering peaks cannot be observed in raw scattering profiles, they actually exist. Subtracting free-melt scattering and multiplying by q 4 benefit the observation of these weak scattering peaks. With the new Fourier transform method, it was found that indeed as proposed previously, thicker lamellar crystals exist in the structured melt. To determine the lateral size of residual lamellar crystal especially, a new method was developed under the guidance of the new theory. With the new method, it was found that although the crystallinity is very low (∼1% at 174°C), the lateral sizes in the structured melts are still large, e.g. 45.3 nm at 174°C, much greater than the critical nucleation size. This implies that these residual lamellar crystals can act as athermal nuclei after quenching to a lower temperature, as proposed by Ziabicki & Alfonso [(1994). Colloid Polym. Sci. 272, 1027-1042; (2002). Macromol. Symp. 185, 211-231] more than 20 years ago. The methodologies proposed here could also be applied to other polymer lamellar systems.

Poly(Acrylonitrile-Butadiene-Styrene) as a Special β-Nucleating Agent on the Toughness of Isotactic Polypropylene

The influence of poly(acrylonitrile–butadiene–styrene) (ABS) as a special β-nucleating agent on the impact and tensile properties of isotactic polypropylene (iPP) were investigated by dynamic rheological measurements, wide-angle X-ray diffraction (WAXD), differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and mechanical properties tests. It is found that the β nucleation efficiency of ABS is closely related to its concentration, dispersibility, and molding method for the iPP/ABS blends. The content of β-crystal (K_β) rises with the incorporation of ABS and shows a maximum with the introduction of 1% ABS for compression-molded blends and 2% ABS for injection-molded blends, respectively, which is followed by a decrease in K_β. The addition of a small amount of ABS has a significant reinforcing and toughening effect on iPP. Compared with the compression-molded samples, the ABS dispersed phase in injection-molded samples has a smaller particle size and a larger specific surface area, which are favorable for stress transmission and higher β nucleation efficiency, and therefore, better tensile and impact properties can be expected.

A new small-angle X-ray scattering model for polymer spherulites with a limited lateral size of the lamellar crystals

As is well known, polymers commonly form lamellar crystals, and these assemble further into lamellar stacks and spherulites during quiescent crystallization. Fifty years ago, Vonk and Kortleve constructed the classical small-angle X-ray scattering theory (SAXS) for a lamellar system, in which it was assumed that the lamellar stack had an infinite lateral size [Vonk & Kortleve (1967 ▸), Kolloid Z. Z. Polym. 220, 19-24]. Under this assumption, only crystal planes satisfying the Bragg condition can form strong scattering, and the scattering from the lamellar stack arises from the difference between the scattering intensities in the amorphous and crystalline layers, induced by the incident X-ray beam. This assumption is now deemed unreasonable. In a real polymer spherulite, the lamellar crystal commonly has dimensions of only a few hundred nanometres. At such a limited lateral size, lamellar stacks in a broad orientation have similar scattering, so interference between these lamellar stacks must be considered. Scattering from lamellar stacks parallel to the incident X-ray beam also needs to be considered when total reflection occurs. In this study, various scattering contributions from lamellar stacks in a spherulite are determined. It is found that, for a limited lateral size, the scattering induced by the incident X-ray beam is not the main origin of SAXS. It forms double peaks, which are not observed in real scattering because of destructive interference between the lamellar stacks. The scattering induced by the evanescent wave is the main origin. It can form a similar interference pattern to that observed in a real SAXS measurement: a Guinier region in the small-q range, a signal region in the intermediate-q range and a Porod region in the high-q range. It is estimated that, to avoid destructive interference, the lateral size needs to be greater than 11 µm, which cannot be satisfied in a real lamellar system. Therefore, SAXS in a real polymer system arises largely from the scattering induced by the evanescent wave. Evidence for the existence of the evanescent wave was identified in the scattering of isotactic polypropyl-ene. This study corrects a long-term misunderstanding of SAXS in a polymer lamellar system.

A Study of the Pressure-Induced Solidification of Polymers

By using a self-designed pressure-jump apparatus, we investigated the melt solidification behavior in the rapid compression process for poly-ethylene-terephthalate (PET), polyether-ether-ketone (PEEK), isotactic polypropylene (iPP), high-density polyethylene (HDPE), and the living polymer sulfur. The experimental results clearly show that crystallization could be inhibited, and some melts were solidified to the full amorphous state for PET, PEEK, and sulfur. Full amorphous PEEK that was 24 mm in diameter and 12 mm in height was prepared, which exceeded the size obtained by the melt quenching method. The bulk amorphous sulfur thus obtained exhibited extraordinarily high thermal stability, and an abnormal exothermic transition to liquid sulfur was observed at around 396 K. Since the solidification of melt is realized by changing pressure instead of temperature and is not essentially limited by thermal conductivity, it is a promising way to prepare fully amorphous polymers. In addition, novel properties are also expected in these polymers solidified by the pressure-jump within milliseconds.

Thirty Years of Modeling of Injection Molding. A Brief Review of the Contribution of UNISA Code to the Field

UNISA code, a software for the analysis and modeling of injection molding, was born at the University of Palermo in Italy in the 1980s. Afterwards, in the 1990s, it was rewritten and expanded at the University of Salerno (Italy) and continuously improved over the years. It is a study code, aimed at understanding rather than simulating. It has the unique characteristic of describing, since the early versions, the morphology of the molded samples. Furthermore, it always implemented the interrelationships among the different material properties (crystallinity, viscosity, density). In this work, the evolution of the software is reviewed, placed in the background, underlining the contribution given to the understanding of polymer processing and morphology evolution. Eventually, the future challenges of modeling are presented.

Crystallization and Mechanical Properties of Polypropylene under Processing-Relevant Cooling Conditions with respect to Isothermal Holding Time

For semicrystalline thermoplastics, aside from pressure and shear, the temperature-time behavior while cooling the melt significantly affects the geometry and degree of ordered structures (e.g., spherulite size, degree of crystallization, and crystal modification) and, as a consequence, the resulting global component properties. Previous research has shown that a higher isothermal holding temperature (e.g., mold temperature and chill-roll temperature) leads to the formation of more distinct ordered structures and, therefore, can lead to greater stiffness and strength. Nevertheless, isothermal holding time during manufacturing is typically not taken into account. In this paper, fast scanning calorimetry (FSC) measurements were taken using polypropylene to analyze the crystallization during idealized temperature-time profiles based on the dynamic temperature process and to investigate the crystallization behavior at different temperatures and isothermal holding times analytically. Furthermore, iPP foils were extruded and tested mechanically to investigate the knowledge gained experimentally. Analytical and mechanical results show that foils produced at the same isothermal holding temperature can obtain significantly different ordered structures and mechanical properties depending primarily on the isothermal holding time.

Melt recrystallization behavior of carbon-coated melt-drawn oriented isotactic polypropylene thin films

The melt recrystallization of vacuum carbon evaporated melt-drawn iPP thin films at varying melting temperature, melting time and recrystallization temperature was studied by means of transmission electron microscopy combined with electron diffraction.