Viscoelastic Properties of Polypropylene during Crystallization and Melting: Experimental and Phenomenological Modeling

This paper deals with the viscoelastic behavior during crystallization and melting of semicrystalline polymers, with the aim of later modeling the residual stresses after processing in cases where crystallization occurs in quasi-static conditions (in additive manufacturing for example). Despite an abundant literature on polymer crystallization, the current state of scientific knowledge does not yet allow ab initio modeling. Therefore, an alternative and pragmatic way has been explored to propose a first approximation of the impact of crystallization and melting on the storage and loss moduli during crystallization-melting-crystallization cycles. An experimental approach, combining DSC, optical microscopy and oscillatory shear rheology, was used to define macroscopic parameters related to the microstructure. These parameters have been integrated into a phenomenological model. Isothermal measurements were used to describe the general framework, and crystallization at a constant cooling rate was used to evaluate the feasibility of a general approach. It can be concluded that relying solely on the crystalline fraction is inadequate to model the rheology. Instead, accounting for the microstructure at the spherulitic level could be more useful. Additionally, the results obtained from the experiments help to enhance our understanding of the correlations between crystallization kinetics and its mechanical effects.

Crystallization of Polymers in Processing Conditions: An Overview

In polymer processing, crystallization generally occurs in complex, inhomogeneous and coupled mechanical (flow, pressure), thermal (cooling rate, temperature gradient) and geometrical (surface of processing tools) conditions. A first route to understand crystallization in processing conditions is to design model experiments to isolate the specific influence of a given parameter. The emphasis will be laid here on the influence of: (i) shear flow through rheo-optical measurements using the commercial RheoScope module, (ii) high cooling rates obtained with the modified hot stage Cristaspeed (up to 2 000 °C min−1) and (iii) high pressures in the original Cristapress cell (up to 200 MPa). Numerical simulation is also a useful tool to understand and predict the coupled phenomena involved in crystallization. Based on Avrami's ideas and equations, a general differential formulation of overall crystallization kinetics has been proposed by Haudin and Chenot (2004). It is able to treat both isothermal and non-isothermal cases, and has been extended to crystallization in a limited volume without and with surface nucleation inducing transcrystallinity.

CRISTAPRESS: an optical cell for structure development in high-pressure crystallization

An original optical high-pressure cell, named CRISTAPRESS, has been especially designed to investigate phase transitions of complex liquids, i.e., polymers, polymer blends, nano-composites, etc. The design of the cell is based on the optical properties of morphological entities through in situ light depolarizing microscopic observations. Pressure up to 200 MPa with a fine temperature control up to 300 °C can be applied. A striking advantage of this cell is the possibility to select the pressure transmitting medium that can be water, silicone oil, a fluid in the supercritical state, etc. The potential of the novel technique was demonstrated by carrying out time-resolved measurements during polymer crystallization induced by water pressure. These preliminary experimental investigations permit to discriminate the role of the barometric and thermal histories on the kinetics of polymer growth, as well as on the subsequent morphologies. It should lead to new reliable crystallization kinetics models.

Numerical and Physical Modeling of Polymer Crystallization

Crystallization of thin polypropylene films was performed in isothermal, constant cooling-rate and mixed conditions. The experiments were first analyzed using the classical procedures based on simplified forms (Avrami, Ozawa) of the general Kolmogoroff-Avrami-Evans (KAE) theory. These analyses, which can be applied over an unusually wide transformation range, show that the crystallizations are actually 2 D. Then, a procedure has been established for the determination of the nucleation and growth parameters involved in the theoretical model presented in the first paper of this series. These parameters have been introduced into the model in order to predict the crystallization behavior in isothermal, constant-cooling-rate and mixed-conditions: transformed fraction, number of activated nuclei, final size distribution of semi-crystalline entities. A very good agreement is generally found between predictions and experimental results.

Structure Development in Injection Molding: A 3D Simulation with a Differential Formulation of the Kinetic Equations

The purpose of the present work is to introduce a crystallization law into Rem3D, a 3D code written in C++ and dedicated to the injection molding of polymers. We kept the basic hypotheses of Avrami's model and cast the kinetic equations into a differential system that is solved numerically. The variation of the density of potential nuclei with temperature is taken into account. Furthermore, the distribution of mean spherulite sizes can be deduced from the calculations. The second part of the paper is an experimental study of crystallization in well-controlled conditions (2D, isothermal or constant cooling-rate). It establishes a procedure for the determination of the nucleation and growth parameters used in the theoretical model, and gives a first validation of this model. Finally, the crystallization equations are introduced into Rem3D, in order to assess the feasibility of our new approach. Some typical results concerning the evolution of the transformed volume fraction in injection-molded parts are presented.