Minfang Ana,
Haojun Xua,
You Lva,
Qun Gub,
Feng Tianc and
Zongbao Wang*a
aNingbo Key Laboratory of Specialty Polymers, Faculty of Materials Science and Chemical Engineering, Ningbo University, Ningbo 315211, China. E-mail: wangzongbao@nbu.edu.cn
bCollege of Material Engineering, Ningbo University of Technology, Ningbo 315211, China
cShanghai Institute of Applied Physics, Chinese Academy of Sciences, Shanghai 201204, China
First published on 19th May 2016
An in situ small-angle X-ray scattering (SAXS) study of the structural effects of temperature and draw ratio (DR1) of the hot-drawing process on ultra-high molecular weight polyethylene (UHMWPE) gel fibers was performed with equipment simulating the hot-drawing process on an industrial production line. The UHMWPE gel fibers were prepared from the industrial production line. The results show that the increase of hot-drawing temperature has a significant effect on the kebab but no obvious effect on shish length and misorientation. The increase of temperature is beneficial to the formation of the shish in a suitable temperature range of 124–130 °C, while the formation of the shish at higher temperature, 140 °C, needs higher DR1. Moreover, the increase of DR1 is beneficial to the formation of shish at all experimental hot-drawing temperatures, while the kebab formation mainly occurs at low DR1 and the kebab transformation mainly happens at high DR1. The shish length and misorientation decreases with the increase of DR1.
In order to better investigate the actual structural evolution mechanism of UHMWPE fibers, Tian et al.18,19 investigated the formation and transition of shish-kebab crystal of UHMWPE fibers during ultra-high hot stretching at varying temperature of 80, 90 and 100 °C via in situ small and wide angle X-ray scattering. They believed that the formation of shish structure accompanied by the break-reorganization of original lamellae at low temperature of 80 °C, while shish-kebab structure smoothly transformed to shish structure with no significant break of kebab crystal at 100 °C. But the temperature of hot stretching was much lower than that in practical industrial production line. Moreover, the hot-stretching process, which was adopted by Tian et al. to research the structural evolution of UHMWPE fibers, is very different with the hot-drawing process of practical industrial production line. So these studies can not really reflect the structural evolution of shish-kebab of UHMWPE fibers at different draw ratio and temperature in practical industrial production line.
Small-angle X-ray scattering (SAXS) is the very effective method for the research of the microstructure of polymer materials. Moreover, its theory has been fully developed that can be applied for the measurement of polymer lamellae, polymer microfibrils and microvoids.20–22 Furthermore, with the awareness of the value of synchrotron radiation and continuous development, the in situ X-ray measurements have become available and popular for the various studies.23
In this study, the actual structural effects of temperature and draw ratio on UHMWPE fibers in industrial production line were studied by in situ SAXS. The equipment of simulating the hot-drawing process of industrial production line was installed on the experiment table for in situ SAXS experiment. The UHMWPE fibers sample was gel fibers, which was prepared from the industrial production line.
Sample | s1 (m min−1) | s2 (m min−1) | Drawing temperature (°C) | DR1 |
---|---|---|---|---|
A1 | 0.183 | 0.366 | 124 | 2 |
A2 | 0.183 | 0.549 | 124 | 3 |
A3 | 0.183 | 0.732 | 124 | 4 |
A4 | 0.183 | 0.915 | 124 | 5 |
A5 | 0.183 | 1.098 | 124 | 6 |
B1 | 0.183 | 0.366 | 127.5 | 2 |
B2 | 0.183 | 0.549 | 127.5 | 3 |
B3 | 0.183 | 0.732 | 127.5 | 4 |
B4 | 0.183 | 0.915 | 127.5 | 5 |
B5 | 0.183 | 1.098 | 127.5 | 6 |
C1 | 0.183 | 0.366 | 130 | 2 |
C2 | 0.183 | 0.549 | 130 | 3 |
C3 | 0.183 | 0.732 | 130 | 4 |
C4 | 0.183 | 0.915 | 130 | 5 |
C5 | 0.183 | 1.098 | 130 | 6 |
C6 | 0.183 | 1.281 | 130 | 7 |
D1 | 0.183 | 0.366 | 140 | 2 |
D2 | 0.183 | 0.549 | 140 | 3 |
D3 | 0.183 | 0.732 | 140 | 4 |
D4 | 0.183 | 0.915 | 140 | 5 |
D5 | 0.183 | 1.098 | 140 | 6 |
D6 | 0.183 | 1.281 | 140 | 7 |
D7 | 0.183 | 1.464 | 140 | 8 |
D8 | 0.183 | 1.647 | 140 | 9 |
D9 | 0.183 | 1.830 | 140 | 10 |
![]() | (1) |
![]() | (2) |
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Fig. 2 The 2D SAXS patterns of UHMWPE gel fibers at different temperature and hot-drawing ratio (DR1) and the UHMWPE gel fibers without hot-drawing at room temperature. |
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Fig. 3 SEM images of UHMWPE gel fibers and drawn fibers: (a and b) the gel fibers, (c and d) the drawn fibers at first hot-drawing stage. |
The shish scattering intensity at different temperature and DR1 are shown in Fig. 4a. The value of shish scattering intensity is increased with the increase of DR1, which corresponds to the result of 2D SAXS patterns as shown in Fig. 2. It means that the increase of DR1 is good to the formation of shish. Moreover, the value of shish scattering intensity increases with the increase of temperature when the temperature is below 140 °C. And the shish scattering intensity at 140 °C is obviously lower than that of other three temperatures at the same DR1. But when DR1 is higher than 6, the shish scattering intensity at 140 °C becomes strong. Besides, the gel fibers can obtain higher maximum DR1 at 140 °C than that at other three temperatures. It can be seen from that the high temperature of 140 °C is not good for the formation of shish at low DR1, while the high DR1 is conducive to the formation of shish. These results indicate that the increase of temperature is beneficial to the formation of shish at suitable temperature range, while the formation of shish at high temperature such as 140 °C needs higher DR1.
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Fig. 4 The scattering intensities from shish and kebabs at different temperature and DR1: (a) the scattering intensity of shish, (b) the scattering intensity of kebab. |
Fig. 4b shows the kebab scattering intensity at different temperature and DR1. The kebab scattering intensity firstly increases and then decreases with the increase of DR1. The increase of kebab scattering intensity indicates the formation of kebab (lamellae), while the decrease of kebab scattering intensity means the transformation of kebab to shish. The DR1 of the highest kebab scattering intensity is the transition point of formation and transformation of kebab. When the DR1 is lower than the transition point, the formation of kebab is predominant process in hot-drawing process. In other words, the main process is the transformation of kebab when the DR1 is higher than the transition point. The DR1 of the highest kebab scattering intensity at temperature of 124, 127.5, 130 and 140 °C are 5, 4, 3, and 4, respectively. It can be seen that the transition point moves to the lower DR1 with the increase of temperature when the temperature is lower than 140 °C. This result implies that the increase of temperature is conducive to the transformation of kebab to shish when the temperature is lower than 140 °C, which corresponds to the result of the shish scattering intensity. The reason is that the transformation of kebab to shish is the melting recrystallization process in stretching field in the experimental conditions of this study, which makes the increase of temperature good to the transformation of kebab. Moreover, at relatively low DR1, high temperature is conducive to the formation of shish and kebab, so the scattering intensity of shish and kebab are both improved with the increase of temperature. At relatively high DR1, the molecular chain, which could take part in crystal, all have been crystallized. So the increase of shish scattering intensity corresponds to the decrease of kebab scattering intensity, i.e., higher shish scattering intensity accompanies the lower kebab scattering intensity. As a consequence, the transition point moves to the lower DR1 with the increase of temperature when the temperature is lower than 140 °C. And the temperature has significant influence on the both formation and transformation of kebab at 140 °C due to the fact that the temperature of 140 °C is very close to the melt temperature of UHMWPE fibers, which makes the kebab more thickness form at 140 °C. So the transition point is at 4 DR1, which is not too lower or not too high comparing with temperature that lower than 140 °C. In addition, the kebab scattering intensity at 140 °C is much higher than other three temperatures when DR1 is lower than 6. It means that the kebab which was formed at 140 °C is much larger than that at other three temperatures and difficultly transformed to shish. This is why the shish scattering intensity at 140 °C is lower than other temperatures at the same DR1. But the kebab scattering intensity at 140 °C decreases with the increase of DR1 when DR1 is higher than 4. It indicates that the transformation of kebab at high temperature such as 140 °C needs higher DR1, which corresponds to the formation of shish at 140 °C. Moreover, it should be noted that the kebab scattering intensity is lower than the actual scattering intensity of kebab at relative high DR1 due to the fact that fibers became thinner with the increase of DR1. Therefore the transition point mentioned above is slightly lower than the actual value.
To further study the structural effects of temperature and draw ratio of hot-drawing process on UHMWPE fibers in industrial product line, more parameters about shish and kebab structure were calculated from the SAXS patterns. Two parameters to describe the kebab structure, namely the long period L and the lateral dimension of the kebab, are derived from the SAXS data measured along the meridian. The long spacing of stacks of kebab along the fiber axis direction can be obtained by considering the scattering intensity distribution along the q1 direction I(q1), which was obtained by meridian scans along q1 for certain intervals of q2 as schematically shown in Fig. 2 and 5a. And the long period of the samples, L measured along q1, was calculated from the peak position of I(q1) according to Bragg's law:
L = 2π/q1,max | (3) |
The Δq1, which is shown in Fig. 5a, is the width of peaks at half height of I(q1) curves, which represents the distributions of long period, L. In order to obtain the accurate peak position of I(q1) and Δq1, the one-dimensional SAXS curves were fitted by Lorentz as shown in Fig. 5a.
The lateral size of kebab structure LSAXS can be derived from the width Δq2 of the peaks at half height in the equatorial direction according to the following equation:27
LSAXS = 2π/Δq2 | (4) |
The Δq2 was obtained by Lorentz fitting, which is shown in Fig. 5b.
The average shish length, 〈Lshish〉, and the misorientation of shish, Bϕ, were obtained by using the Ruland streak method to analyze the meridional streak feature in SAXS.28–30 Ruland demonstrated that the size and orientation distributions of longitudinal voids in polymer and carbon fibers in real space could be estimated from the meridional streak of SAXS in reciprocal space (as long as the orientation and the longitudinal length of scatterer are finite). Since the method is principally based on the separation of experimentally measured azimuthal breadth from contributions of scatterer length and misorientation, the method can also be applied to separate the average length of shish and its average misorientation. If one assumes that all azimuthal distributions can be modeled by Lorentz functions, the observed azimuthal width, Bobs, can be related to the length of shish, 〈Lshish〉, and the azimuthal width, Bϕ, due to misorientation of shish by the following equation.
![]() | (5) |
If all azimuthal distributions have Gaussian expressions, then the relationship becomes
![]() | (6) |
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Fig. 6 Plot of azimuthal integral width (Bobs) vs. the value of 1/s, which was used to determine the average shish length (〈Lshish〉) and the shish misorientation (Bϕ) based on eqn (5). |
Fig. 7 shows the one-dimensional SAXS scattering intensity distribution curves along q1 direction of UHMWPE gel fibers hot-drawing at different temperature and DR1. The scattering intensity firstly increases and then decreases with the increase of DR1 at 124, 127.5, 130 and 140 °C, which corresponds to the result of kebab scattering intensity. Moreover, the peak position, q1,max, which decides the value of long period, L, firstly increases and then decreases with the increase of DR1 at 124, 130 and 140 °C. But when the temperature at 127.5 °C, q1,max firstly decreases then increases and finally decreases with the increase of DR1. The information from Fig. 7 is relatively apparent, so the more information about the kebab structure needs to obtain from the value of long period, L.
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Fig. 7 One-dimensional SAXS scattering intensity distribution curves along q1 direction of UHMWPE gel fibers hot-drawing at different temperature and DR1. |
The long period and the distribution of long period of UHMWPE gel fibers hot-drawing at different temperature and DR1 are shown in Fig. 8. The long period is increased with the temperature and the distribution of long period decreases with the increase of temperature, which is attributed to the decrease of the number of kebab with the increase of temperature due to the fact that the nucleation ability of kebab on shish became weaker with the increase of temperature. But kebab structure is more perfect and bigger with the increase of temperature because that high temperature is good to the growth of kebab crystals. In addition, the long period at hot-drawing temperature of 124, 130 and 140 °C firstly decrease and then increase, but long period at 127.5 °C firstly increases slightly then decreases and finally increases. The first slight increase at hot-drawing temperature of 127.5 °C should be caused by calculation deviation. So the basic trend of long period is firstly decreased at relative low DR1 and then increased at relative high DR1, which corresponds to the results of kebab intensity. It can be known from Fig. 8b that the distribution of long period at 124, 127.5, 130 and 140 °C decreases with the increase of DR1, which means the long period become more homogeneous with the increase of DR1. Moreover, the main structural process of hot-drawing is the formation of kebab at relative low DR1, while the transformation of kebab to shish occupies the main process of hot-drawing process at relative high DR1. Combining the result of kebab scattering intensity as shown in Fig. 4b, the decrease of long period at relative low DR1 was attributed to the formation of more kebabs. And the increase of long period at relative high DR1 was caused by the transformation of kebab to shish, which indicates that more kebab transformed to shish with the increase of DR1.
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Fig. 8 (a) The long period of UHMWPE gel fibers hot-drawing at different temperature and DR1, (b) the distribution of long period of UHMWPE gel fibers hot-drawing at different temperature and DR1. |
Fig. 9 shows the one-dimensional SAXS scattering intensity distribution curves along q2 direction of UHMWPE gel fibers hot-drawing at different temperature and DR1. The variations of intensity with the increase of DR1 at different temperatures are same as those of Fig. 7. The lateral size of kebab structure of UHMWPE gel fibers hot-drawing at different temperature and DR1 is shown in Fig. 10. It can be seen that the kebab lateral size is increased with the temperature. The result implies that higher temperature is good to the formation of kebab with bigger lateral size. Besides, the kebab lateral size firstly increases and then decreases with the increase of DR1. The increase of kebab lateral size indicates that low DR1 at hot-drawing process is conducive to the formation of kebab with bigger lateral size. Moreover, the increase of kebab lateral size seems to accord with the result of kebab scattering intensity as shown in Fig. 4. The decrease of kebab lateral size was caused by the transformation of kebab to shish and the formation of kebab with smaller lateral size at relative high DR1. The decrease of kebab lateral size at later hot-drawing process corresponds to the previous study results.19,31,32
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Fig. 9 One-dimensional SAXS scattering intensity distribution curves along q2 direction of UHMWPE gel fibers hot-drawing at different temperature and DR1. |
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Fig. 10 The lateral size of kebab structure of UHMWPE gel fibers hot-drawing at different temperature and DR1. |
The average shish length (〈Lshish〉) and the shish misorientation (Bϕ) of UHMWPE gel fibers hot-drawing at different temperature and DR1 are shown in Fig. 11. It can be easily seen from Fig. 11a that the average shish length at all hot-drawing temperature decreases with the increase of DR1. The decrease of shish length was attributed to the entanglement, which made the shish difficult to growth longer at later stage of hot-drawing process. Moreover, the shish misorientation is also decreased with the increase of DR1 at all hot-drawing temperature, which is due to that hot-drawing at higher DR1 make more shish oriented. With the variation of temperature, no obvious variation trend about average shish length and shish misorientation can be obtained from Fig. 11, which indicates that the hot-drawing temperature has no significant influence on shish length and misorientation.
On the basis of the previous experimental results and analysis, a schematic diagram is proposed to describe the microstructural evolution of UHMWPE gel fibers during one-step hot-drawing, as shown in Fig. 11. Before the hot-drawing process, the lamellae in UHMWPE gel fibers are randomly oriented as shown in Fig. 12a. When the hot-drawing process with low DR1 is carried out, the original lamellae transforms to the new shish-kebab crystals with good orientation as shown in Fig. 12b. With the DR1 further to increase, the kebab gradually transforms to microfibril (imperfect shish) structure and the shish length gradually decreases. Finally, not all kebabs transform to microfibril due to the break of the fibers at high DR1 as shown in Fig. 12c, which indicates that the further transformation of kebab needs next step hot-drawing at higher temperature before the fibers breaking at first-step hot-drawing process.
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Fig. 12 Schematic diagram of the microstructural evolution of UHMWPE gel fibers in one-step hot-drawing process. |
This journal is © The Royal Society of Chemistry 2016 |