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DOI 10.1007/s00397-014-0775-1
ORIGINAL CONTRIBUTION
Received: 5 December 2013 / Revised: 8 March 2014 / Accepted: 7 April 2014 / Published online: 31 May 2014
© Springer-Verlag Berlin Heidelberg 2014
Abstract In this paper, the effect of shear on the flow- to convert raw materials (mainly polyolefins) to final plastic
induced crystallization (FIC) of several polypropylenes of products. The raw materials used in these polymer pro-
various macrostructures was studied using rheometry com- cessing methods are often subjected to mixed shear and
bined with polarized microscopy. Generally, an increase in extensional flow conditions, which cause the polymer to
strain and strain rate or decrease of temperature is found experience flow-induced crystallization (FIC). The mechan-
to decrease the thermodynamic barrier for crystal formation ical and optical properties of the final products are strongly
and thus enhancing crystallization kinetics at temperatures dependent upon the processing method and the conditions
between the melting and crystallization points. Secondly, under which crystallization takes place (Eder et al. 1990;
popular models based on suspension theory which are used McHugh and Edwards 1995; Kumaraswamy et al. 1999;
to relate the degree of crystallinity to normalized rheological Kornfield et al. 2002; Janeschitz-Kriegl 2003; Scelsi and
functions (such as viscosity) are validated experimentally. Mackley 2008).
For this purpose, the space filling of crystals in the polarized The kinetics of crystallization considerably improves
micrographs determined from image processing was plotted under flow at temperatures comparable to the melting peak
as a function of normalized viscosity under various shear temperature and is related to both strain and strain rates
rates. It is found that the constant(s) of various suspension (Eder et al. 1998; Gelfer and Winter 1999; Kitoko et al.
models should be dependent on the flow parameters in order 2003; Swartjes et al. 2003; Stadlbauer et al. 2004; Tanner
for the suspension models to describe the effect of shear on and Qi 2005, 2009; Dai et al. 2006; Hadinata et al. 2006;
FIC, particularly at higher shear rates. Chellamuthu et al. 2011; Tiang and Dealy 2012; White et al.
2012). Moreover, different types of flow deformation affect
Keywords Flow-induced crystallization · Polypropylene · FIC differently. For instance, in the case of fiber spinning
Quiescent crystallization · Halftime crystallization and film blowing, extensional flows account for the orienta-
tion and stretching of polymer molecules in the direction of
extension, thus enhancing the crystallization process signif-
Introduction icantly. Online fiber spinning data related to flow-induced
crystallization behavior of several polypropylenes (PPs)
Processes such as film blowing, film casting, fiber spinning, have been reported (Paradkar et al. 2008; Patel et al. 2008).
calendaring, and injection molding are still used extensively Shearing also enhances the crystallization kinetics; how-
ever, since it is inherently a weaker flow compared to exten-
sional flow, larger strains are required to see the effect of
M. Derakhshandeh · S. G. Hatzikiriakos () flow on crystallization (Hadinata et al. 2007; Derakhshan-
Department of Chemical and Biological Engineering, deh and Hatzikiriakos 2012). High shear rate data obtained
The University of British Columbia, Vancouver, BC, Canada using a special sliding plate rheometer was reported for
e-mail: savvas.hatzi@ubc.ca
poly-1-butene (Baert and Van Puyvelde 2006). At low shear
A. K. Doufas rates, the crystallization kinetics was enhanced mainly by
ExxonMobil Chemical Company, Baytown, TX, USA inducing a higher nucleation density. Further increasing in
520 Rheol Acta (2014) 53:519–535
the shear rate imposed oriented structures (Baert and Van polarized microscopy with some of the effects studied here
Puyvelde 2006). have also been addressed previously by others (Coppola
There are relatively few available data in the literature et al. 2004; Hadinata et al. 2005; Jay et al. 1999; Baert et al.
on the importance of different types of flows on crystalliza- 2006; Acierno et al. 2003; Duplay et al. 2000; Bourgin and
tion and even less data that address the effects of molecular Zinet 2010; Kim et al. 2005). However, in this paper, six
weight parameters on crystallization (Chellamuthu et al. different PP resins exhibiting different behavior in terms of
2011; Eder et al. 1998; Tanner and Qi 2005; Baert and Van nucleation (as observed by polarized optical microscopy)
Puyvelde 2006; Tiang and Dealy 2012; White et al. 2012). and crystal growth rate are studied. The data provided
Therefore, it is an objective of this paper to examine in this paper can be the basis for obtaining the model
the role of temperature and shear flow on the crystalliza- parameters which can be further validated by comparison
tion kinetics of several polypropylenes of various molecular with FIC behavior under extensional and/or mixed flows.
weights and polydispersities. In particular, the effects of A comprehensive model should predict crystallization
important parameters for crystallization such as strain rate, behavior under quiescent, shear, extensional, and mixed
strain, temperature, and molecular parameters are examined flow conditions at various temperatures. Moreover, as
under simple shear using rheometry coupled with polarized mentioned by Duplay et al. (2000), extra care should be paid
microscopy. when resins produced by different technologies are studied
An effective method of optimizing any industrial-scale and compared.
process and/or improving the quality of the final prod-
uct is by performing numerical simulations of the process.
To put this into perspective, in the film blowing process, Material and methods
the locked-in stresses at the frost line (location of transi-
tion from liquid to solid) dictates the tensile strength of Six different PPs with different molecular weights and poly-
the produced material (Han and Kwack 1983; Kwack and dispersities were used in this work, all provided by the
Han 1983; Kuijk et al. 1999). Numerical simulation of this ExxonMobil Chemical Company. These resins are listed
process and its further optimization heavily depend on the in Table 1 along with their molecular weight characteris-
accuracy of the models, and for the process under discus- tics (molecular weight, Mw ; polydispersity index (PDI =
sion, a reliable model for FIC is crucial (Doufas et al. Mw /Mn ), melt flow rate, mass flow rate (MFR), and tac-
1999, 2000; Doufas and McHugh 2001; Doufas 2013). In ticity). The molecular weights (weight average molecular
such models, the degree of crystallinity is often related to weight Mw and number average molecular weight Mn ) were
normalized rheology functions (NRF) by various models determined using High-Temperature Gel-Permeation Chro-
derived from the suspension theory. These models bene- matography (Polymer Laboratories PL-GPC-220) equipped
fit from being easy to implement into simulation; however, with a differential refractive index detector (DRI) (Sun et al.
they have their own limitations such as not being applicable 2001). Carbon NMR (13 C) spectroscopy was used to mea-
to higher deformation rates. Therefore, the second objec- sure the tacticity of the studied polypropylenes in terms of
tive of this paper is to evaluate suspension models which percent molar meso pentads (mmmm). 13 C NMR spectra
are typically used to relate the system zero-shear-rate vis- were acquired with a 10-mm broadband probe on a Varian
cosity with the degree of crystallization. A light microscope spectrometer having a 13 C frequency of at least 100 MHz.
equipped with a polarizer and an analyzer is used with a The samples were prepared in 1,1,2,2-tetrachloroethane-d2
parallel-plate rheometer in order to determine the degree of (TCE). Sample preparation (polymer dissolution) was per-
crystallization at various deformation rates. These data sub- formed at 140 ◦ C where 0.25 g of polymer was dissolved
sequently are used to evaluate the applicability of various in an appropriate amount of solvent to give a final polymer
suspension models in describing the degree of crystallinity solution of 3 ml.
under flow. Previous methods related NRF with relative
crystallinity obtained from independent differential scan- Differential scanning calorimetry
ning calorimetry (DSC) measurements (Acierno et al. 2003;
Boutahar et al. 1998; Lamberti et al. 2007; Pantani et al. A Shimadzu DSC-60 calorimeter was used to study the
2001; Titomanlio et al. 1997). In the present paper, the rhe- thermal behavior of PPs. Nitrogen purge was used in order
ological functions and degree of crystallization are obtained to avoid degradation of the test specimens. Melting and
simultaneously, thus avoiding possible errors from a differ- crystallization peaks of polymers were obtained by using
ent thermal history experienced by the test specimens as multiple heating and cooling protocols applied to 1–2 mg
shown below. of sample directly harvested from pellets sealed in an alu-
In summary, shear effects on the FIC of a variety of minum pan. The exact experimental protocol is shown in
PPs is studied here using shear rheometry combined with Fig. 1. Thermal and flow histories were eliminated by
Rheol Acta (2014) 53:519–535 521
heating each sample at the rate of 10 ◦ C/min from 50 to halftimes of crystallization of all resins at specific values of
200 ◦ C and soaking it at 200 ◦ C for 15 min. Eventually, T = 0.25, 0.5, and 0.75 on the same graph.
the temperature was decreased to 50 ◦ C at 10 ◦ C/min which
was followed by reheating to 200 ◦ C using the same rate in Shear rheometry
order to obtain the crystallization and melting temperature
peaks, respectively. History elimination was confirmed by An Anton Paar rotational rheometer (MCR 502) was used
obtaining a third cycle, where the crystallization and melting to study the shear rheology of samples. Polypropylene pel-
peaks were found almost identical to those obtained in the lets were melted at the temperature of 200 ◦ C and then were
second cycle. The melting and crystallization peaks Tm and pressed in a compression molding apparatus to produce
Tc , respectively, are summarized in Table 1, and the values sheets with a thickness of about 1 mm. The shear-induced
represent the averages of three different samples. crystallization behavior of polymers was examined in sim-
The halftime of isothermal crystallization was deter- ple shear flow using the parallel-plate geometry with plates
mined at different temperatures between the determined of 25 mm in diameter. These experiments are confined to
crystallization, Tc , and melting, Tm , DSC peaks. These were the temperature region between the crystallization and the
defined in DSC thermograms as the time required for a sam- melting peaks found in the DSC thermograms under the
ple to reach 50 % of its final crystallinity at the designated heating and cooling modes. This temperature range is of
crystallization temperature. The percent of crystallinity as great importance in FIC due to the tendency of molecules to
a function of time was calculated by integrating the area crystallize and reorient. Since higher temperatures impede
underneath the peak of the DSC thermogram. the crystallization kinetics excessively, FIC at higher tem-
Since the investigated PP resins exhibit different melting peratures is extremely time-consuming. The crystallization
and crystallization peaks, the isothermal crystallization for behavior of resins at shear rates larger than 2 s−1 could
the various resins was studied at fixed values of a normal- not be investigated considering edge failure effects on the
ized temperature defined by T = (T − TC ) (Tm − TC ). measured torque. Thermal and flow histories of the sam-
This enables also a consistent and fair comparison of the ples were eliminated by heating up each test specimen to
200 ◦ C (around 40 ◦ C above the melting peak tempera-
ture) for 15 min prior to cooling at the rate of 10 ◦ C/min
DSC protocol to the desired temperature and experimental testing. Fast
200 History
and accurate cooling is crucial to reach the desired crystal-
Elimination
on
Cooling
Validation
that would lead into premature crystallization. The Peltier
Elimination
Temperature, T (oC)
Peak De
150 system of the rheometer was used for this study since it
Peak De
100
History
location. For modeling purposes, the induction times are in any image processing techniques. Therefore, the errors
usually defined at small levels of crystallinity (∼1–2 %), contributing to this technique is minimized by obtaining
and therefore the crystallization phenomenon which starts clear images at a gap size of about 0.5 mm. Since the rela-
from the outer edge has a minimal effect on the rheological tive crystallinity and the NRF are obtained using the same
behavior captured at the induction time. When the crystal- experiment, the temperature and shear deformation histories
lization further increases, the polymer shrinks, and thus the which are imposed on the samples are identical, which is an
underlying equations used for the rheological characteriza- advantage of this experimental method.
tion are not applicable without modifications regardless of
the geometry used (Godara et al. 2006).
Results and discussion
Polarized light microscopy
Linear viscoelasticity of the polypropylenes
Polarized light microscopy (Mitutoyo microscope setup
equipped with a Lumenera LU 165 color CCD camera and The master curves of the linear viscoelastic moduli of all
two polarizers) was used in conjunction with an Anton Paar PPs studied at the reference temperature of 190 ◦ C produced
MCR502 in order to study the crystalline structure evolution by the application of the time-temperature superposition
formed under different conditions. In a typical experiment, (TTS) technique is depicted in Fig. 2a–f (Ferry 1980). For
the sample (disk) is placed in the space between two glass the low molecular weight materials, the Newtonian region
plates of the rheometer (parallel-plate geometry of 43 mm (e.g., PP1, PP2) at low frequencies was reached. For the
in diameter) and the microstructure is observed with the high molecular weight materials (PP4, PP5, and PP6), stress
microscope as a function of time. The space filling of crys- relaxation experiments after imposing a sudden strain were
tals in the polarized images was calculated through image also performed to obtain data over a wide range of frequen-
analysis as a function of time and then converted to the cies. This is possible by converting the relaxation modulus
degree of crystallinity by using the densities of crystal and to dynamic data at very low frequencies in order to deter-
polymer melt (0.94 and 0.85 g/cm3 ), respectively (Natta mine the zero-shear viscosity (Schwarzl method) (Ferry
et al. 1955). The calculated crystallinity under quiescent 1980). This procedure was used just for three of the PPs
conditions at different temperatures was compared to crys- in this study, i.e., the high molecular weight resins. The
tallinity obtained using DSC so as to validate the polarized continuous lines in Fig. 2a–f represent fits of the multi-
microscopy applicability. mode Maxwell model {Gi, λi}which show that this model is
As discussed above, the microscopy videos were decom- capable of representing the data very well.
piled to frames which were analyzed by an image process- Figure 3 plots the complex viscosity of all PPs as a func-
ing software (Matlab and ImageJ) in order to calculate the tion of frequency at the reference temperature of 190 ◦ C.
amount of space filling. Two different image processing This figure is in agreement with the MFR values of the
methods were utilized to validate the obtained results. In the resins listed in Table 1. The resin with the larger viscosity
first approach, the grayscale filter was first applied to all has higher resistance to flow, and thus, it has a lower MFR.
extracted images to set each pixel value to a single number Table 2 lists the activation energy for flow, Ea , using the
that represents the brightness of the pixel. The pixel format shift factors obtained from the construction of the master
is typically the byte image which gives a range of possi- curves depicted in Figs. 2 and 3. The Arrhenius model was
ble values from 0 to 255. Frequently, zero is taken to be used:
black, while 255 are taken as white. Values in between 0 and
Ea 1 1
255 construct different shades of gray. Each pixel value was aT = exp − − (1)
R T Tref
normalized between 0 and 1 in Matlab in order to define
a threshold. All pixels within the microscopy images were where Ea is the activation energy for flow, a measure of the
converted into black or white based on the specified thresh- sensitivity of the viscoelastic properties to temperature. It
old, which was estimated by Matlab and further tuned by the can be seen that PP5 has the highest energy of activation,
user. Eventually, the space filling was estimated as the ratio Ea .
of the number of white pixels to the total number of pixels
within the image. In the second approach, the area of crys- Thermal behavior of the polymer
tals was estimated by the area of circles with the same center
and radios as that of the crystals. In this method, any overlap Figure 4a depicts a typical thermogram of one of the PPs
between the circles is considered once. Circles were drawn (PP3 in Table 1). The melting and the crystallization peak
manually and then processed by ImageJ software. Image temperatures were observed at 160.5 and 115 ◦ C, respec-
quality plays a significant role in acquiring accurate results tively. As shown in Fig. 4b, the thermomechanical history
Rheol Acta (2014) 53:519–535 523
a b
d
c
e f
Fig. 2 a–f Master curves of the viscoelastic moduli of all PPs listed in Table 1 at the reference temperature of Tref = 190 ◦ C
causes a difference of 2.5 ◦ C between the first heating peak normalized temperature, T for all PP resins. This normal-
(163.0 ◦ C) and the melting peak temperature (160.5 ◦ C). ization of the temperature facilitates the comparison of
The difference between the second and third heating peaks halftimes of crystallization for various resins as discussed
is only 0.2 ◦ C, which is within experimental error. This above. At very low normalized temperatures (i.e., close to
further indicates that the sample soaking time of 15 min crystallization peak), the halftime of crystallization for all
at 200 ◦ C is long enough to eliminate the thermal his- polypropylenes are very small as normally expected. In this
tory (Fig. 4b). Similar comments apply to the crystalliza- region (T < 0.2), the halftimes of crystallization of differ-
tion/cooling peaks as well as to the DSC results for all other ent resins show a small difference of 5 %, which is within
samples listed in Table 1. experimental error. The crystallization kinetics varies signif-
Figure 5 plots the quiescent halftimes of crystalliza- icantly between various resins as the temperature increases.
tion obtained from DSC thermograms as a function of the The difference is potentially attributed to differences in (i)
524 Rheol Acta (2014) 53:519–535
Heat, Q (mW)
DSC thermogram of PP3 for
Heat, Q (mW)
three consecutive
heating/cooling cycles. Thermal 0
history elimination is
demonstrated by the small
differences obtained between First heating
-5 Tm=160.5oC Second and third peak
second and third melting peaks
heating peak
a b
-5
100 200 150 155 160 165 170 175
o o
Temperature,T ( C) Temperature,T ( C)
before reaching its steady state. The times for the onset significantly. In the parallel-plate geometry, the shear defor-
of crystallization and transient to reach its steady state are mation rate varies linearly with radial position, being zero
comparable as shown in the graph. In addition, nucleation at the center and attains its highest value at the edge. The
that evolved during the cooling period (due to the low tem- effect of this nonhomogeneous shearing on the nucleation
perature) also contributes to this deviation. As seen from density of PP1 is shown in Fig. 10. The nucleation density
Fig. 9, the temperature has a noticeable effect on the induc- increases significantly from the center (Fig. 10a) to the edge
tion time. A decrease of roughly 10 ◦ C (for example, from (Fig. 10c). Moreover, shear also induces crystal alignment
T = 0.5 to 0.25) causes the onset of crystallization to with the highest alignment and nuclei density close to the
occur at times of roughly 1 order of magnitude earlier. In edge of the parallel-plate geometry.
general, crystallization kinetics is significantly enhanced as Figure 11 depicts the shear stress growth coefficient as
temperature decreases. a function of the time for various imposed shear rates at
The gradual increase of viscosity as the crystallization T = 0.5 for PP1. A larger shear rate stretches and ori-
begins can be used to determine the induction time which is ents molecules more effectively after a certain strain. This
arbitrarily defined as the time at which a 20 % of increase of activates more nuclei which is also supported by more
the viscosity is obtained. These induction times correspond spherulites of smaller size in the microscopy images (Huo
to a small degree of crystallinity (typically 1–2 %) and if the et al. 2004). Therefore, a larger deformation rate decreases
true viscosity is measured in parallel plate (i.e., γ̇ reported the induction time for the onset of crystallization by enhanc-
at r = 0.75 R), the increase in torque caused by crystal- ing the nucleation density (Fig. 10) and possibly crystal
lization does not influence the induction time measurements growth rates as mentioned in previous studies (Duplay et al.
2000).
Figure 12 plots the shear stress growth coefficient data
10000
of Fig. 11, this time as function of strain. Typically,
PP1
the required shear strain for the onset of crystallization
PP2 increases with increase of the applied deformation rate. In
8000 PP3 other words, more strain is needed at higher shear rates to
Crystallization half time, thalf (s)
PP4
PP5 initiate crystallization. In particular, at the shear rates of
6000
PP6 0.01 s−1 , a strain of 70 is required to initiate crystallization,
while at the shear rate of 0.1 s−1 , crystallization occurs after
600 strain units. This is in agreement with experimental
4000
results reported by other authors (Eder et al. 1998; D’Haese
et al. 2010). The increase of the amount of strain with the
2000 increase of shear rate for the onset of crystallization (see
Fig. 12) is a counterintuitive observation.
Figure 13 shows the effect of shear rate on the induc-
0
tion time for all PPs studied. Open symbols in Fig. 13 are
0.0 0.1 0.2 0.3 0.4 0.5 0.6
obtained from rheometry as described above, while closed
Normalized temperature, T symbols are obtained by DSC. As seen, flow enhances and
Fig. 5 The quiescent (DSC) halftimes of crystallization of all PPs as speeds up the onset of crystallization mainly at rates greater
a function of the normalized temperature, T than a certain critical value. At deformation rates smaller
526 Rheol Acta (2014) 53:519–535
than this value, the flow does not disturb the molecules region (γ̇ < γ̇critical ), the crystallization behavior is essen-
from their equilibrium configurations, and thus no effect tially similar to that of quiescent condition. Larger shear
on their crystallization behavior occurs. Therefore, over this rates (γ̇ > γ̇critical ) activate more nuclei causing a dramatic
30 30
rate on the shear stress growth a b
coefficient η+ of PP1 at the
shear rates of a 0.005 s−1 and b
0.1 s−1 at T = 142.4 ◦ C or 10 10
T = 0.5
PP1
.
PP1 = 0.1000 s-1
. T=0.5
= 0.005 s-1
T=0.5 1oC/min
o
1oC/min 5 C/min
5oC/min 10oC/min
10oC/min 20oC/min
20oC/min 30oC/min
1 1
102 103 104 102 103 104
Time, t (s) Time, t (s)
Rheol Acta (2014) 53:519–535 527
Fig. 10 Crystal density observed at various radial positions in the parallel-plate geometry for PP1 at T = 0.5 and shear rate of 2 s−1 a at center
of the geometry, b at r = 0.75R, and c r = R, with crystal alignment to increase with the radial position
The intersection of these two lines defines the critical shear are formed (Janeschitz-Kriegl et al. 2003). These behav-
rate required to start observing the effect of flow. These iors were also supported by various works done previously
critical shear rates for all resins studied are summarized in (D’Haese et al. 2010, 2011). PP4 has the highest nucleation
Table 3. As mentioned by Acierno and Grizzuti (2003), the density among all of the investigated resins (i.e., closer to
orientation of chains under shearing (low Weissenberg num- the saturated state), and thus a higher critical shear rate is
ber) is sufficient to enhance the crystallization phenomenon needed to enhance the quiescent crystallization kinetics as
by inducing a higher nucleation rate compared to quies- seen in Table 3. As previously mentioned, applying flow
cent conditions (Godara et al. 2006; Devaux et al. 2004; usually causes the polymer to induce a higher nuclei density.
Koscher and Fulchiron 2002). Large deformation rates (i.e., PP2 uses a different catalyst for its production and thus can-
large Weissenberg numbers) stretch chains in the direction not be compared with the other resins. The different catalyst
of flow, changing the mechanism of crystallization from system for production can introduce a different growth rate
spherulitic to rodlike nucleation which further facilitates the and kinetics since it imposes different molecular structures
kinetics of crystallization. POM images in our case sug- (Wunderlich 1976). PP5 and PP3 have very similar tacticity
gest spherulitic crystallization at low Weissenberg numbers and PDI. PP5 has a higher molecular weight in compari-
(typically of the order of 1). son with PP3 and thus shows lower critical shear rate for
It was hypothesized earlier that dormant nuclei exist flow-enhanced crystallization. Although PP6 has the high-
within polymer matrix. These precursors are activated by est molecular weight and PDI, it exhibits a higher critical
imposing undercooling and/or applying deformation rates shear rate than PP5, PP3, and PP1 due to its lower tacticity.
(Janeschitz-Kriegl and Ratajski 2005; Janeschitz-Kriegl Tacticity seems to play a major role in FIC.
et al. 2003). Higher deformation rates and higher degree of Figure 15 depicts the effect of shear rate on the
undercooling activate more dormant nuclei. It was assumed induction time at various normalized temperatures for PP1.
and supported by experimental data that at very high defor- DSC results for T = 0.75 could not be obtained since
mation, the nucleus density saturates, and no more nuclei the heat of crystallization which is released at this high
temperature is not detectable by the DSC apparatus used.
The induction time increases by 1 order of magnitude for a
change of roughly of 10 ◦ C. On the same time, an increase
of shear rate from 0 to 0.5 decreases the induction time by a
factor of 2.
Quiescent crystallization of resins at desired tempera- the density of crystals (0.94 g/cm3 ) and that of the melt
tures was investigated by both optical microscopy and DSC (0.85 g/cm3 ) (Natta et al. 1955). The relative crystallinity
in order to experimentally validate the accuracy of this obtained from the optical microscopy was compared to that
setup. As a first step, the relative crystallinity of PP as obtained from DSC to check for accuracy of the optical
a function of time was calculated by integrating the area microscopic technique.
underneath the peak of the DSC thermogram and then nor- Table 4 shows typical microscopy images before and
malizing it by the total area. In a second step, the degree after image processing with methods 1 and 2 described in
of space filling of crystals in the polarized images was the experimental section. A satisfactory agreement between
calculated from optical microscopy by using the image pro- the DSC and image processing results was found, as can
cessing techniques described above. The degree of space
filling was converted to degree of crystallization using
Fig. 14 The effect of shear rate on the induction time for the onset
Fig. 13 The effect of shear rate on the induction time for the onset of of crystallinity for PP6 and PP2 at T = 0.5. A critical shear
crystallinity for all PPs at T = 0.5. The closed symbols correspond to rate is observed at which transition from quiescent to flow-induced
the halftime quiescent crystallization obtained from DSC crystallization occurs
530 Rheol Acta (2014) 53:519–535
Table 3 The critical shear rate above which the effect of flow on is essential in order to capture the true crystallization behav-
crystallization becomes evident at T = 0.5 ior of resins. Previous works typically measured the relative
Resin Critical shear rate (s−1 ) crystallinity from DSC and then relate it with rheological
measurements (Acierno et al. 2003; Boutahar et al. 1998;
PP1 0.02 Lamberti et al. 2007; Pantani et al. 2001; Titomanlio et al.
PP2 0.31 1997). As depicted in Fig. 17, the data at very low shear rate
PP3 0.03 (γ̇ < 0.5 s −1 ) shows comparable crystallization behavior.
PP4 0.10 Increasing the shear rates alters the crystal-melt interaction
PP5 0.02 and thus causes the normalized viscosity to show upturns at
PP6 0.06 lower degrees of space fillings (crystallizations).
Material Before image processing After image processing - method 1 After image processing - method 2
PP5
Morphology structure of PP5 Morphology structure of PP5 Morphology structure of PP5
after 685s at 138.8 ◦ C after 685s at 138.8 ◦ C after 685s at 138.8 ◦ C
the following equation, while Frankel and Acrivos (1967) Richmond 1980; Kitano et al. 1981; Kataoka et al. 1978).
suggested Eq. 4: The latter is useful for the concentrated suspension of par-
ticles of any shape with A being a shape coefficient (for
η 5 ∅
= exp × (3) instance, A = 0.68 for smooth spheres):
ηa 2 1−∅ − 5 ×∅max
∅max η
= 1 − ∅ ∅max
2
(5)
1/ ηa
∅ 3
η 9 ∅max η −2
= × (4) = 1−∅A (6)
ηa 8 1/ ηa
1 − ∅ ∅max
3
To compare the capabilities of these equations, we have
The last two formulae which were studied in this work have set the adjustable parameters in such a way that all models
a similar form and were proposed by Ball and Richmond result in the same induction time at low shear rates. This
in 1980 (Eq. 5) and Kitano et al. in 1981 (Eq. 6) (Ball and induction time corresponds to the space filling required to
Conclusions
obtain normalized viscosity ratio, η/ηa of 1.2. The param-
eters which were used in the models are listed in Table 5. Flow-induced crystallization of several PP samples under a
The formulation of Frankel and Acrivos (Eq. 4) predicts an simple shear was studied in this work in order to elucidate
NRF of zero instead of one at zero degree of space filling the effects of flow deformation relative to quiescent con-
as shown in Fig. 17. Equations 3 and 5 exhibit the strongest ditions. In simple shear, there is a critical strain required
NRF dependence on the degree of space filling. Equations 2 for the onset of crystallization at given shear rates and tem-
and 6 show a similar trend and seem to predict the relation peratures. In shear experiments, the critical strain needed
between space filling and NRF better. Experimental data for a polymer to crystallize decreases with decreasing rate.
under a higher shear rate of 0.5 and 2 s−1 could not be Temperature was found to be an important variable in crys-
predicted by using the same model constants; therefore, A tallization as expected, and a change of temperature by a few
constant in Eq. 6 was reduced by a factor of 50 to mimic degrees changes the induction times for crystallization by 1
the behavior properly (see dash line curve in Fig. 17). The order of magnitude. The suspension models are applicable
suspension models are applicable at low deformation rates, only to low deformation rates, since there is only a depen-
since there is only a dependence of the viscosity on the dence of the viscosity on the degree of filling. A proper
degree of filling, but there is no explicit dependence on the model should have a viscoelastic constitutive equation basis
deformation rate (Newtonian-like models). A proper con- in order to be able to capture the crystallization behavior
stitutive equation for suspensions, however, should include well (e.g., the two-phase constitutive/microstructural model
both the degree of filling (crystallinity) and the deforma- for FIC of Doufas et al. (2000) and Doufas (2013)).
tion rate dependencies. For relatively small shear rates (e.g.,
≤0.1 s−1 in our case), the regime of viscosity of the New-
tonian plateau at the testing temperature is reached, and the Acknowledgments Financial assistance from the Natural Sciences
and Engineering Research Council (NSERC) of Canada, the scholar-
NRF vs. degree of space filling experimental curves more ship program of the University of British Columbia (4YF), and the
ExxonMobil Chemical are gratefully acknowledged.
Table 5 Models’ parameter used to predict the results in Fig. 17
crystallinity which needs to be quantified in order to explain The heat transfer equations for the polymer and the quartz
the differences between the POM and DSC results with plate located on top of the polymer (Fig. 18) are as follows:
reference to Fig. 16a.
ρpolymer Cp,polymer ∂T 1 ∂
∂t = r ∂r kpolymer r ∂T ∂
∂r + ∂z kpolymer
∂T
∂z + q̇
Crystal formation releases heat within the polymer at a
ρquartz Cp,quartz ∂T 1 ∂ ∂T ∂ ∂T
∂t = r ∂r kquartz r ∂r + ∂z kquartz ∂z
rate of
(8)
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