Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene
In this study, the relationships between processing, structure and properties of self-reinforced ultra-high molecular weight polyethylene (UHMWPE) composites fabricated via thermal pressing are investigated. By systematically varying processing temperatures (145, 155, 165, 170, 175,180 °C) and pres...
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Gruppo Italiano Frattura
2025-08-01
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| Series: | Fracture and Structural Integrity |
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| Online Access: | https://fracturae.com/index.php/fis/article/view/5503 |
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| author | Eugene Statnik Dmitry D. Zherebtsov Dilus I. Chukov Ilya I. Larin Alnis A. Veveris Valerii G. Torokhov Alexander S. Kechekyan Kristina Z. Myagkova Iuliia A. Sadykova Alexey I. Salimon Alexander M. Korsunsky Semen D. Ignatyev Kamal M. Hammad Sergey D. Kaloshkin |
| author_facet | Eugene Statnik Dmitry D. Zherebtsov Dilus I. Chukov Ilya I. Larin Alnis A. Veveris Valerii G. Torokhov Alexander S. Kechekyan Kristina Z. Myagkova Iuliia A. Sadykova Alexey I. Salimon Alexander M. Korsunsky Semen D. Ignatyev Kamal M. Hammad Sergey D. Kaloshkin |
| author_sort | Eugene Statnik |
| collection | DOAJ |
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In this study, the relationships between processing, structure and properties of self-reinforced ultra-high molecular weight polyethylene (UHMWPE) composites fabricated via thermal pressing are investigated. By systematically varying processing temperatures (145, 155, 165, 170, 175,180 °C) and pressures (25 and 50 MPa), we demonstrate that mechanical performance is governed by the interplay between fiber consolidation and the preservation of the oriented crystalline phase. Scanning electron microscopy reveals the presence of residual voids that are independent of the processing parameters, and which lead to interfacial failure and fibrillar fracture morphologies. We identify a critical processing threshold at 165 °C (25 MPa), which yields peak interlayer shear strength (7.8–11.1 MPa), bending strength (102–130 MPa), elastic modulus (23–42 GPa), and Charpy impact resistance (72–95 kJ/m²). Beyond this threshold, however, mechanical performance deteriorates due to fiber remelting and loss of anisotropy, resulting in the composite transitioning to an isotropic UHMWPE matrix. Conversely, elevated pressures fail to improve properties due to insufficient macromolecular interdiffusion, which is the dominant bonding mechanism. These findings establish a processing-structure-property framework for UHMWPE-based self-reinforced composites that balances interfacial adhesion and crystalline alignment, while providing actionable guidelines for engineering high-performance single-polymer materials.
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| format | Article |
| id | doaj-art-bcd66721a73e4f4ebb7ce11868dcb48c |
| institution | Kabale University |
| issn | 1971-8993 |
| language | English |
| publishDate | 2025-08-01 |
| publisher | Gruppo Italiano Frattura |
| record_format | Article |
| series | Fracture and Structural Integrity |
| spelling | doaj-art-bcd66721a73e4f4ebb7ce11868dcb48c2025-08-26T06:52:14ZengGruppo Italiano FratturaFracture and Structural Integrity1971-89932025-08-01197410.3221/IGF-ESIS.74.10Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight PolyethyleneEugene Statnik0https://orcid.org/0000-0002-1105-9206Dmitry D. Zherebtsov1https://orcid.org/0000-0001-5134-475XDilus I. Chukov2Ilya I. Larin3Alnis A. Veverishttps://orcid.org/0000-0002-7497-1112Valerii G. Torokhov4https://orcid.org/0000-0003-0811-3731Alexander S. Kechekyan5Kristina Z. Myagkova6Iuliia A. Sadykova7Alexey I. Salimon8https://orcid.org/0000-0002-9048-8083Alexander M. Korsunsky9https://orcid.org/0000-0002-3558-5198Semen D. Ignatyev10https://orcid.org/0000-0001-7415-5513Kamal M. Hammad11https://orcid.org/0009-0004-6051-5222Sergey D. Kaloshkin12Center for Digital Engineering, Skoltech, Russia, CASM&T, MAI, Russia Laboratory of Accelerated Particles <<LUCh>>, NUST MISIS, RussiaCenter for Composite Materials, NUST MISIS, RussiaCenter for Composite Materials, NUST MISIS, RussiaCenter for Translational Medicine, Sirius University of Science and Technology, RussiaCenter for Composite Materials, NUST MISIS, RussiaN.S. Enikolopov Institute of Synthetic Polymer Materials, Russian Academy of Sciences, Moscow, RussiaN.S. Enikolopov Institute of Synthetic Polymer Materials, Russian Academy of Sciences, Moscow, RussiaCenter for Digital Engineering, Skoltech, Russia, CASM&T, MAI, RussiaCenter for Digital Engineering, Skoltech, Russia, CASM&T, MAI, RussiaCenter for Digital Engineering, Skoltech, Russia, CASM&T, MAI, RussiaFBES FSCH named after F.F. Erisman of the Rospotrebnadzor, Mytishchi, RussiaCenter for Digital Engineering, Skoltech, RussiaCenter for Composite Materials, NUST MISIS, Russia In this study, the relationships between processing, structure and properties of self-reinforced ultra-high molecular weight polyethylene (UHMWPE) composites fabricated via thermal pressing are investigated. By systematically varying processing temperatures (145, 155, 165, 170, 175,180 °C) and pressures (25 and 50 MPa), we demonstrate that mechanical performance is governed by the interplay between fiber consolidation and the preservation of the oriented crystalline phase. Scanning electron microscopy reveals the presence of residual voids that are independent of the processing parameters, and which lead to interfacial failure and fibrillar fracture morphologies. We identify a critical processing threshold at 165 °C (25 MPa), which yields peak interlayer shear strength (7.8–11.1 MPa), bending strength (102–130 MPa), elastic modulus (23–42 GPa), and Charpy impact resistance (72–95 kJ/m²). Beyond this threshold, however, mechanical performance deteriorates due to fiber remelting and loss of anisotropy, resulting in the composite transitioning to an isotropic UHMWPE matrix. Conversely, elevated pressures fail to improve properties due to insufficient macromolecular interdiffusion, which is the dominant bonding mechanism. These findings establish a processing-structure-property framework for UHMWPE-based self-reinforced composites that balances interfacial adhesion and crystalline alignment, while providing actionable guidelines for engineering high-performance single-polymer materials. https://fracturae.com/index.php/fis/article/view/5503Self-reinforced composite (SRC)Ultra-high molecular weight polyethylene (UHMWPE)Scanning electron microscopy (SEM)interlayer shear testCharpy impact testbending |
| spellingShingle | Eugene Statnik Dmitry D. Zherebtsov Dilus I. Chukov Ilya I. Larin Alnis A. Veveris Valerii G. Torokhov Alexander S. Kechekyan Kristina Z. Myagkova Iuliia A. Sadykova Alexey I. Salimon Alexander M. Korsunsky Semen D. Ignatyev Kamal M. Hammad Sergey D. Kaloshkin Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene Fracture and Structural Integrity Self-reinforced composite (SRC) Ultra-high molecular weight polyethylene (UHMWPE) Scanning electron microscopy (SEM) interlayer shear test Charpy impact test bending |
| title | Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene |
| title_full | Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene |
| title_fullStr | Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene |
| title_full_unstemmed | Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene |
| title_short | Parameters Optimization for Manufacturing Advanced Self-Reinforced Composites based on Ultra-High Molecular Weight Polyethylene |
| title_sort | parameters optimization for manufacturing advanced self reinforced composites based on ultra high molecular weight polyethylene |
| topic | Self-reinforced composite (SRC) Ultra-high molecular weight polyethylene (UHMWPE) Scanning electron microscopy (SEM) interlayer shear test Charpy impact test bending |
| url | https://fracturae.com/index.php/fis/article/view/5503 |
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