Deformation kinetics of single-fiber polypropylene composites: Adhesion improvement at the expense of toughness

Despite the maturity of the technology, processing of fiber-reinforced thermoplastic materials remains challenging, and difficulties in processability often result in material formulations with high modulus and strength, yet rather poor ductility compared to the pure polymer matrix. To gain fundamental insight into the deformation mechanisms present in such materials, the complexity of the system is step-wise increased; first, the effect of the most commonly applied adhesion enhancement, the addition of MAH-g-PP compatibilizer, on the bulk properties is assessed. The small-strain tensile properties, i.e., modulus and yield stress, appear to be only marginally affected by the addition of such compatibilization agent, however, the strain-at-break is strongly reduced, even before the addition of the fiber reinforcement. Subsequently, using in-situ X-ray characterization methods upon tensile deformation, the time evolution of crystal structure and lamellar morphology is determined, and at first glance the compatibilizer addition appears to better preserve the crystalline structure. The onset of local failure (cavitation) is quantified at the interface of a single glass fiber. By increasing the adhesive interaction between fiber and matrix the stress concentration at the interface is increased, leading to an acceleration in void formation followed by unstable growth, which in turn strongly embrittles the composite. By the addition of various selective nucleating agents, it is demonstrated that the role of local phase composition and morphology on the deformation kinetics and subsequent failure mechanisms is much more pronounced than the increased adhesion between fiber and matrix by compatibilization or sizing effects. These findings may specify a new route towards tougher fiber-reinforced composites with reduced complexity in the material formulation.