Influence of processing conditions and physicochemical interactions on morphology and fracture behavior of a clay/thermoplastic/thermosetting ternary blend

This study provides information on the mechanical behavior of epoxy-poly(methyl methacrylate) (PMMA)-clay ternary composites, which have been prepared using the phase separation phenomenon of PMMA and the introduction of organophilic-modified montmorillonites (MMTs), the continuous matrix being the epoxy network. Two dispersion processing methods are used: a melt processing without any solvent and an ultrasonic technique with solvent and a high-speed stirrer. TEM analysis shows that phase separation between PMMA and the epoxy network was obtained in the shape of spherical nodules in the presence of the clay in both process methods used. Nanoclay particles were finely dispersed inside thermosetting matrix predominantly delaminated when ultrasonic blending was used; whereas micrometer-sized aggregates were formed when melt blending was used. The mechanical behavior of the ternary nanocomposites was characterized using three-point bending test, dynamic mechanical analysis (DMA), and linear elastic fracture mechanics. The corresponding fracture surfaces were examined by scanning electron microscopy to identify the relevant fracture mechanisms involved. It was evidenced that the better dispersion does not give the highest toughness because ternary nanocomposites obtained by melt blending present the highest fracture parameters (KIc). Some remaining disordered clay tactoids seem necessary to promote some specific toughening mechanisms. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010