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Experimental and simulation studies of flow of a slipping polymer melt in a co-rotating twin screw extruder are presented. The experiments involve a wide range of polyolefins (polyethylene, isotactic polypropylene, isotactic polybutene-1, isotactic poly 4 methylpentene-1, and a cyclopolyolefin) with an octadecanoic acid additive. Mooney's capillary method is used to prove the occurrence and magnitude of slippage. In the twin screw extruder experiments, the die pressure is reduced for the compounds with octadecanoic acid compared to the neat polyolefins. Screw characteristic curves were determined experimentally for both the polyolefin compounds and the neat polyolefins. These were found to be rather close. We modeled flow of a slipping non-Newtonian(power law) fluid in a screw channel and calculated screw characteristic curves. These were found to be close to our experimental observations.

We have studied the structural characteristics of the cross-sections of injection molded parts of various crystalline polyolefins including polyethylene (PE), isotactic polypropylene (PP), isotactic poly(butene-1) (PB1) and isotactic poly(4-methylpentene-1) (P4MP1). Polarized light microscopy, birefringence and wide angle x-ray diffraction pole figure analysis were used to investigate the samples. In most cases, high orientations were observed near the mold wall and isotropic molded part cores were found. However, highly oriented mold core regions were found in P4MP1. Significantly different types of crystalline orientation near the mold wall were observed among the various polyolefins. We represent the development of these differences through the components of a crystalline orientation tensor which represent changes in the state of orientation between melts in the mold prior to crystallization and the final crystalline molded part.

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