Multiscale characterisation of single synthetic fibres: Surface morphology and nanomechanical properties.

HYPOTHESIS: Thermal through-air bonding process and slip additive treatment affect fibre surface structure and nanomechanical properties, which is extremely difficult to characterise on a single-fibre level. EXPERIMENTS: Optical microscopy (OM) was applied to study the effect of air-through bonding, spunbonding, and crimping on fibre geometry and general appearance. A "spray-on" method developed here using a custom-designed fibre holder allowed a direct measurement of static contact angles of water droplets on single fibres. Scanning electron microscopy (SEM) showed different morphological features on the fibre due to the nonwoven fabric-making process and additive treatment. Synchrotron X-ray diffraction (XRD) was applied to study the effect of erucamide presence on polypropylene (PP) fibre crystal structure. Atomic force microscopy (AFM) imaging provided complementary characterization of fibre topographic features such as average surface roughness, along with adhesion force mapping by quantitative nanomechanical (QNM) AFM imaging. FINDINGS: Our results show the effect of nonwoven making process and surfactant additive treatment on the fibre surface structure and nanomechanical properties. Wettability experiment on the single fibre revealed the hydrophobic nature of all the synthetic fibres. For polyethylene/polyethylene terephthalate (PE/PET) bicomponent single fibres, the polyethylene sheath was found to possess fibrillar microstructure - typical for drawn fibres, whereas the fibres entangled in nonwoven fabrics exhibited a uniform, porous surface morphology attributed to the through-air process. Adhesion force mapping allowed us to correlate fibre nanomechanical properties with its topography, with surface pore interiors showing higher adhesion than the flat polyethylene region. Furthermore, on the polypropylene (PP) fibre surface treated with erucamide (13-cis-docosenamide; a common slip additive used in polyolefin film processing), we observed overlapping multilayers consisting of 4 nm erucamide bilayers, attributed to the slip additive migration onto the fibre surface. XRD measurements of the fibres did not detect the presence of erucamide; however, AFM imaging provided evidence for its migration to the fibre surface, imparting influence on the surface structure and adhesive properties of the fibre. Single-fibre AFM imaging also allowed a detailed analysis of different surface roughness parameters, revealing that both through-air bonding in the nonwoven making process and the slip additive (erucamide) treatment affected the fibre surface roughness. The wettability, surface morphology, and adhesion properties from this study, obtained with unprecedented resolution and details on single fibres, are valuable to informing rational design of fibre processing for fibre optimal properties, critically important in many industrial applications.