Tensile Fracture of Welded Polymer Interfaces: Miscibility, Entanglements, and Crazing

Large-scale molecular simulations are performed to investigate tensile failure of polymer interfaces as a function of welding time t. Changes in the tensile stress, mode of failure and interfacial fracture energy G(I) are correlated to changes in the interfacial entanglements as determined from primitive path analysis. Bulk polymers fail through craze formation, followed by craze breakdown through chain scission. At small t welded interfaces are not strong enough to support craze formation and fail at small strains through chain pullout at the interface. Once chains have formed an average of about one entanglement across the interface, a stable craze is formed throughout the sample. The failure stress of the craze rises with welding time and the mode of craze breakdown changes from chain pullout to chain scission as the interface approaches bulk strength. The interfacial fracture energy G(I) is calculated by coupling the simulation results to a continuum fracture mechanics model. As in experiment, G(I) increases as t(1/2) before saturating at the average bulk fracture energy G(b). As in previous simulations of shear strength, saturation coincides with the recovery of the bulk entanglement density. Before saturation, G(I) is proportional to the areal density of interfacial entanglements. Immiscibiltiy limits interdiffusion and thus suppresses entanglements at the interface. Even small degrees of immiscibility reduce interfacial entanglements enough that failure occurs by chain pullout and G(I) << G(b).