Effect of Processing Variables on Tensile Modulus and Morphology of Polyethylene/Clay Nanocomposites Prepared in an Internal Mixer

A comparative study on effect of internal mixer on high density Polyethylene (HDPE)/clay nanocomposites preparation was done. Effect of temperature, rotor rotation (rpm), and mixing time, as well as rotor type (Roller and Banbury) on mechanical properties and morphology of HDPE/clay nanocomposites were studied using Box-Behnken experimental design. The model was developed according to secant modulus and confirmed to morphology analysis using Transmission Electron Microscopy (TEM). The finding suggests that there is different mechanisms occurred in each rotor to improve the mechanical properties. The mechanism in Roller is medium shear and medium diffusion, while Banbury is high shear and low diffusion. The difference in mechanism to disperse the clay particles attribute to the different optimum processing conditions in each rotor. The settings for roller samples are predicted around mid temperature, mid speed, and mid mixing time. There is no optimum setting for Banbury within the processing boundaries. The best settings for Banbury are at low, high, low settings. The morphology results showed a hybrid composite structure, with some exfoliations and some intercalations. There was a correlation between better mechanical properties and morphology with more exfoliation and thinner intercalated particles.