The Rheology of Polyether Ether Ketone Concentrated Suspensions for Powder Molding and 3D Printing.

The main goal of the work was to use rheological methods for assessing the properties of a composition based on polyether ether ketone (PEEK) to determine the concentration limits of the polymer in the composition and select the optimal content of this composition for powder molding. The rheological properties of highly filled suspensions based on PEEK and paraffin, as well as in paraffin-polyethylene mixtures at various component ratios, were studied. These materials are designed for powder injection molding and 3D printing. Suspensions with a PEEK powder content above 50% are not capable of flow and, with increasing pressure, slide along the surface of the channel. For compositions with a higher content (60 and 70 vol.%) PEEK, independence of the storage modulus from frequency is observed, which is typical for solids and confirms the assignment of such suspensions to elastic-plastic media. The introduction of high-density polyethylene into the composition helps improve the technological properties of suspensions, expanding the range of fluidity, although it leads to an increase in viscosity. In suspensions with a mixed composition of the liquid phase, with increasing temperature, a decrease in the storage modulus is observed at 120 °C and, on the contrary, an increase at 180 °C. The latter may be a consequence of the evaporation of paraffin and the softening of PEEK due to the approach to the glass transition temperature of the polymer. Suspensions with 40% PEEK content have an optimal set of rheological properties for powder injection molding. A 3D printing filament was also obtained from a composition with 40% PEEK, which had good technological properties for FDM 3D printing. Products of satisfactory quality from suspensions with 50% PEEK can be produced by powder injection molding, but not by 3D printing. The selected compositions were used to obtain real PEEK products for practical applications.

Rheology of Highly Filled Polymer Compositions-Limits of Filling, Structure, and Transport Phenomena.

The current state of the rheology of various polymeric and other materials containing a high concentration of spherical solid filler is considered. The physics of the critical points on the concentration scale are discussed in detail. These points determine the features of the rheological behavior of the highly filled materials corresponding to transitions from a liquid to a yielding medium, elastic-plastic state, and finally to an elastic solid-like state of suspensions. Theoretical and experimental data are summarized, showing the limits of the most dense packing of solid particles, which is of key importance for applications and obtaining high-quality products. The results of model and fine structural studies of physical phenomena that occur when approaching the point of filling the volume, including the occurrence of instabilities, are considered. The occurrence of heterogeneity in the form of individual clusters is also described. These heterogeneous objects begin to move as a whole that leads to the appearance of discontinuities in the suspension volume or wall slip. Understanding these phenomena is a key for particle technology and multiphase processing.

Rheology of Gels and Yielding Liquids.

In this review, today's state of the art in the rheology of gels and transition through the yield stress of yielding liquids is discussed. Gels are understood as soft viscoelastic multicomponent solids that are in the incomplete phase separation state, which, under the action of external mechanical forces, do not transit into a fluid state but rupture like any solid material. Gels can "melt" (again, like any solids) due to a change in temperature or variation in the environment. In contrast to this type of rheology, yielding liquids (sometimes not rigorously referred to as "gels", especially in relation to colloids) can exist in a solid-like (gel-like) state and become fluid above some defined stress and time conditions (yield stress). At low stresses, their behavior is quite similar to that of permanent solid gels, including the frequency-independent storage modulus. The gel-to-sol transition considered in colloid chemistry is treated as a case of yielding. However, in many cases, the yield stress cannot be assumed to be a physical parameter since the solid-to-liquid transition happens in time and is associated with thixotropic effects. In this review, special attention is paid to various time effects. It is also stressed that plasticity is not equivalent to flow since (irreversible) plastic deformations are determined by stress but do not continue over time. We also discuss some typical errors, difficulties, and wrong interpretations of experimental data in studies of yielding liquids.

The Elasticity of Polymer Melts and Solutions in Shear and Extension Flows.

This review is devoted to understanding the role of elasticity in the main flow modes of polymeric viscoelastic liquids-shearing and extension. The flow through short capillaries is the central topic for discussing the input of elasticity to the effects, which are especially interesting for shear. An analysis of the experimental data made it possible to show that the energy losses in such flows are determined by the Deborah and Weissenberg numbers. These criteria are responsible for abnormally high entrance effects, as well as for mechanical losses in short capillaries. In addition, the Weissenberg number determines the threshold of the flow instability due to the liquid-to-solid transition. In extension, this criterion shows whether deformation takes place as flow or as elastic strain. However, the stability of a free jet in extension depends not only on the viscoelastic properties of a polymeric substance but also on the driving forces: gravity, surface tension, etc. An analysis of the influence of different force combinations on the shape of the stretched jet is presented. The concept of the role of elasticity in the deformation of polymeric liquids is crucial for any kind of polymer processing.

The Role of Structure in Polymer Rheology: Review.

The review is devoted to the analysis of the current state of understanding relationships among the deformation-induced structure transformations, observed rheological properties, and the occurrence of non-linear effects for polymer liquids (melts, solutions, and composites). Three levels of non-linearity are the base for consideration. The first one concerns changes in the relaxation spectra of viscoelastic liquids, which are responsible for weak non-linear phenomena. The second one refers to the strong non-linearity corresponding to such changes in the structure of a medium that leads to the emergence of a new relaxation state of a matter. Finally, the third one describes the deformation-induced changes in the phase state and/or the occurring of bifurcations and instability in flow and reflects the thermodynamic non-linear behavior. From a structure point of view, a common cause of the non-linear effects is the orientation of macromolecules and changes in intermolecular interaction, while a dominant factor in describing fluid dynamics of polymer liquids is their elasticity. The modern understanding of thixotropic effects, yielding viscoplastic materials, deformation-induced phase transition, and the experimental observations, demonstrating direct correlations between the structure and rheology of polymer liquids, are the main objects for discussion. All these topics are reviewed and discussed mainly on the basis of the latest five-year publications.

Rheology of Highly Concentrated Suspensions with a Bimodal Size Distribution of Solid Particles for Powder Injection Molding.

Powder injection molding (PIM) is one of the modern and prospective technologies in processing different materials. We proposed to use bimodal compositions of particles for increasing their content in the final products. A set of model suspension of Al with low-molecular-weight poly (ethylene glycol) as a binder based on theoretical arguments concerning the filling capacity of bimodal suspensions was prepared. Studying the rheological properties of these compositions showed that they demonstrate elasto-viscous behavior with significant plasticity that is favorable for the technological process. Using compositions with bimodal distributions allows for increasing the content of the solid phase up to 75 vol. % for PIM technology, which is significantly higher than the standard practical limit. This rheological approach developed for model formulations was applied to processing compositions containing aluminum oxide as typical ceramics and polyolefines as a binder widely used in technological practice. The obtained sintered ceramic samples have quite acceptable mechanical properties of the usual corundum articles.

Multiblock Copolymers of Norbornene and Cyclododecene: Chain Structure and Properties.

We investigate the structure-property relations of the multiblock copolymers of norbornene with cyclododecene synthesized via the macromolecular cross-metathesis reaction between amorphous polynorbornene and semicrystalline polydodecenamer in the presence of the first-generation Grubbs catalyst. By adjusting the reaction time, catalyst amount, and composition of the initial system, we obtain a set of statistical multiblock copolymers that differ in the composition and average length of norbornene and dodecenylene unit sequences. Structural, thermal, and mechanical characterization of the copolymers with NMR, XRD, DSC (including thermal fractionation by successive self-nucleation and annealing), and rotational rheology allows us to relate the reaction conditions to the average length of crystallizable unit sequences, thicknesses of corresponding lamellas, and temperatures of their melting. We demonstrate that isolated dodecenylene units can be incorporated into crystalline lamellas so that even nearly random copolymers should retain crystallinity. Weak high-temperature endotherms observed in the multiblock copolymers of norbornene with cyclododecene and other cycloolefins could indicate that the corresponding systems are microphase-separated in the melt state.

Rheological Properties of Fish Gelatin Modified with Sodium Alginate.

Polyelectrolyte complexes of sodium alginate and gelatin obtained from cold-blooded fish were studied for potential application as structure-forming agents in food hydrogels. The mass ratio of sodium alginate to gelatin plays a decisive role in the sol-gel transition and rheological behavior of the complexes. Differences in the sol-gel transition temperature were observed upon heating and cooling, as is typical for such materials. We investigated the characteristics of this transition by measuring the isothermal changes in the elastic modulus over time at a constant frequency and the transition temperature at a range of frequencies. The kinetic nature of this transition depends on the composition of the complexes. A characteristic alginate-gelatin mass ratio is the ratio at which maximum transition temperature as well as elastic modulus and viscosity (rheological parameters) values are obtained; the characteristic mass ratio for these complexes was found to be 0.06. Calculation of the ionic group ratios in the biopolymers that form complexes and comparison of these data with the turbidimetric titration results clarified the origin of these maxima. Measuring the viscoelastic properties and the creep-elastic recoil of the samples allowed us to characterize these materials as viscoelastic media with a viscosity in the order of 103-104 Pa·s and an elastic modulus in the order of 102-103 Pa. These values drastically decrease at a certain stress threshold, which can be treated as the gel strength limit. Therefore, the observed rheological behavior of gels formed by fish gelatin modified with sodium alginate characterizes them as typical viscoelastic soft matter.

Effect of Composition and Interfacial Tension on the Rheology and Morphology of Heavy Oil-In-Water Emulsions.

Rheological and morphological properties of heavy crude oil-in-water (O/W) emulsions have been studied. Two series of emulsions were considered: first, the surfactant type remained constant, while the continuous phase content was varied and second, the surfactant type was varied while the continuous phase content remained constant. Under stress-controlled shearing, all samples exhibit viscoplastic behavior. The rheological properties are directly related to the morphology of the emulsions which vary in size of dispersed phase droplets and their inherent structure. Adding a surfactant characterized by a high value of interfacial oil-water tension results in a decrease in the yield stress (which is a measure of the interparticulate structure strength). The same effect is attained by increasing the water content. Meanwhile, these two factors determine the viscosity which can be much lower than that of the basic heavy crude oil if the O/W type of emulsions has been created. Special attention was paid to the viscoelastic properties which have been scarcely reported. Correlations were found between the surfactant properties, composition of the emulsion, and rheological characteristics of emulsions (yield stress, apparent viscosity, and viscoelastic properties), which allows for reduction in the crude oil viscosity down to a low enough level acceptable for pipe transportation.

Deformation Properties of Concentrated Metal-in-Polymer Suspensions under Superimposed Compression and Shear.

Concentrated metal-in-polymer suspensions (55 and 60 vol.%) of aluminum powder dispersed in low molecular weight polyethylene glycol) demonstrate elastoplastic properties under compression and shear. The rheological behavior of concentrated suspensions was studied in a rotational rheometer with uniaxial compression (squeezing), as well as shearing superimposed on compression. At a high metal concentration, the elasticity of the material strongly increases under strain, compared with the plasticity. The elastic compression modulus increases with the growth of normal stress. Changes in the shear modulus depend on both normal and shear stresses. At a low compression force, the shear modulus is only slightly dependent on the shear stress. However, high compression stress leads to a decrease in the shear modulus by several orders with the growth of the shear stress. The decrease in the modulus seems to be rather unusual for compacted matter. This phenomenon could be explained by the rearrangement of the specific organization of the suspension under compression, leading to the creation of inhomogeneous structures and their displacement at flow, accompanied by wall slip. The obtained set of rheological characteristics of highly loaded metal-in-polymer suspensions is the basis for understanding the behavior of such systems in the powder injection molding process.

Spreading of Oil-in-Water Emulsions on Water Surface.

This work presents the spreading behavior of oil-in-water (o/w) emulsions on the water surface recorded using a high-speed photography method. We study a series of o/w emulsions with two different droplet sizes of 4.50 and 0.75 µm and volume fractions of the oil phase in the 20-80% range. Results show that for all the emulsions a rapid spreading occurs upon the collision with the water surface, which then forms a thin film expanding with time. Appearance of a dry spot in the center of collision is observed in the spreading of the emulsions in midvolume fraction range that induces a bursting-like spreading. For the highly concentrated emulsions, the deliberation of decompression energy from the deformed oil phase droplets inhibits the bursting, increases the equilibrium propagation radius, and reduces the dissipation time. The role of viscoplasticity (existing of the yield stress) is considered and a model describing the propagation step of the emulsion spreading is presented. The model shows that the peculiarities of the spreading are determined by the competition between yielding, plastic viscosity, and interfacial tension. By comparing the model prediction and experimental results, it is suggested that the spreading behavior of the emulsions is not only a consequence of the surface tension gradient but also the coalescence of the oil droplets during spreading.

A Novel Technique for Fiber Formation: Mechanotropic Spinning-Principle and Realization.

We present basic experimental data and the theoretical background of a novel technique for fiber spinning from polymer solutions. The principal feature of the advanced process is realization of phase separation with detachment of a solvent, accompanied by the orientation of macromolecules, under the action of high extension rates. This is similar in some respects to dry spinning, though the driving force is not diffusion with subsequent evaporation of a solvent but redistribution of polymer-solvent interactions in favor of polymer-polymer and solvent-solvent ones governed by mechanical stresses. A promise of this approach has been demonstrated by experiments performed with polyacrylonitrile solutions in different solvents and solutions of the rigid-chain aromatic polyamide. We examined mechanotropic fiber spinning in model experiments with stretching jets from a drop of polymer solution in different conditions, and then demonstrated the possibility of realizing this process in the stable long-term continuous mode. During extension, phase separation happens throughout the whole section of a jet, as was confirmed by visual observation. Then a solvent diffuses on a jet surface, forming a liquid shell on the oriented fiber. Instability of this cover due to surface tension leads either to formation of separate solvent drops "seating" on the fiber or to the flow of a solvent down to the Taylor cone. The separate liquid droplets can be easily taken off a fiber. The physics underlying this process is related to the analysis of the influence of macromolecule coil-to-stretched chain transition on the intermolecular interaction.

Physical chemistry of highly concentrated emulsions.

This review explores the physics underlying the rheology of highly concentrated emulsions (HCEs) to determine the relationship between elasticity and HCE stability, and to consider whether it is possible to describe all physicochemical properties of HCEs on the basis of a unique physical approach. We define HCEs as emulsions with a volume fraction above the maximum closest packing fraction of monodisperse spheres, φm=0.74, even if droplets are not of polyhedron shape. The solid-like rheological behavior of HCEs is characterized by yield stress and elasticity, properties which depend on droplet polydispersity and which are affected by caging at volume fractions about the jamming concentration, φj. A bimodal size distribution in HCEs diminishes caging and facilitates droplet movement, resulting in HCEs with negligible yield stress and no plateau in storage modulus. Thermodynamic forces automatically move HCEs toward the lowest free energy state, but since interdroplet forces create local minimums - points beyond which free energy temporarily increases before it reaches the global minimum of the system - the free energy of HCEs will settle at a local minimum unless additional energy is added. Several attempts have been undertaken to predict the elasticity of HCEs. In many cases, the elastic modulus of HCEs is higher than the one predicted from classical models, which only take into account spatial repulsion (or simply interfacial energy). Improved models based on free energy calculation should be developed to consider the disjoining pressure and interfacial rheology in addition to spatial repulsion. The disjoining pressure and interfacial viscoelasticity, which result in the deviation of elasticity from the classical model, can be regarded as parameters for quantifying the stability of HCEs.