Rheology for Wood Plastic Composite Extrusion-Part 1: Laboratory vs. On-Line Rheometry

Common polymeric materials (neat polymers) are quite well known, and their properties are often available in appropriate material databases. However, material data, e.g., rheological data, for materials such as polymer blends, polymer composites (including wood plastic composites), and filled plastics are simply lacking in material databases. This paper addresses the problem of determining viscosity curves for one of the most widely used advanced polymeric materials: wood plastic composites. Studies were conducted in laboratory and production settings, i.e., on-line. Laboratory tests were conducted in two ways: on the basis of classical rheometric measurements, i.e., High-Pressure Capillary Rheometry (HPCR), and on the basis of Melt Flow Index (MFI) measurements, also including tests based on a limited number of measurement points. Tests in production conditions, i.e., on-line, were conducted during the extrusion process using the measurement of the process output (material flow rate) and pressure in a specialized extrusion die. The test results (viscosity curves) obtained from Melt Flow Index (MFI) measurements and on-line measurements were presented and evaluated against the background of the results (viscosity curves) obtained from classical capillary rheometry measurements (HPCR). Due to the lack of rheological data of wood plastic composites in available databases, in-house research methods based on the two-point viscosity curve determination in the plastometric (MFI) tests and the tests under production conditions, that is, on-line, have been proposed. The two-point method, based on the power law model, is quick and easy to implement, and allows for solving many polymer processing issues analytically. On-line tests have the significant advantage of being conducted under the actual flow conditions of the tested material, rather than under laboratory conditions, as is the case with rheometric and plastometric tests, which do not take into account the processing history of the tested material. The issues of rheology and modeling of wood plastic composite processing, e.g., extrusion and injection molding, which have not yet been resolved and require practical solutions, were also discussed. The results of this part of the study (viscosity curves and models) will be used in the second part of the study to evaluate the impact of rheological testing methods and rheological models on the accuracy of process modeling (extrusion).