Production, characterization, and modeling of mineral filled polypropylene filaments

This research produced mineral filled polypropylene filaments using a variety of fillers, characterized these filaments, and attempted to model their mechanical properties with current composite models. Also, these filaments were compared with bone to determine if they are suitable for modeling the mechanical properties of bone. Fillers used consist of wollastonite, talc, calcium carbonate, titanium dioxide, and hydroxyapatite. Fillers and polypropylene chips were combined and extruded into rods with the use of a mixer. The rods were chipped up and then formed into filaments through melt extrusion utilizing a piston extruder. Filaments with volume fractions of filler of 0.05, 0.10, 0.15, and 0.20 were produced. Additionally, some methods of trying to improve the properties of these filaments were attempted, but did not result in any significant property improvements. The fillers and filaments were visually characterized with a scanning electron microscope. Cross-sections, filament outer surfaces, fracture surfaces, and longitudinal cut open surfaces were viewed in this manner. Those filaments with anisotropic filler had some oriented filler particles, while all filaments suffered from poor adhesion between the polypropylene and the filler as well as agglomerations of filler particles. Twenty specimens of each filament were tensile tested and the average tenacity, strain, and modulus were calculated. Filaments containing talc, talc and wollastonite, titanium dioxide, or hydroxyapatite suffered from a drastic transition from ductile to brittle with the addition of 0.05 volume fraction of filler. This is evidenced by the sharp decrease in strain at this volume fraction of filler when compared to the strain of the unfilled polypropylene filament. Additionally, these same filaments suffered a sharp decrease in tenacity at the same volume fraction. These instant decreases are attributed to the agglomerations of filler in the filament. Generally, the modulus of the filaments increased with the increase in concentration of filler. The tensile tenacity, strain, and modulus were modeled with current composite models for particulate filled composites. The tenacity and strain models did not accurately predict the properties of the filaments, while the modulus models were more accurate, perhaps because the agglomerations of filler did not affect the modulus as much as it affected the tenacity and strain of the filaments. Production, characterization, and modeling of these filaments indicates that there are many areas for improvements, such as improved mixing of the filler and polypropylene, increased adhesion between matrix and filler, and decreased agglomerations of filler. Mechanically, these filaments can not match the properties of bone. However, they do have many structural similarities at the micro-mechanical level, so with some improvements in properties these filaments may be suitable models for modeling bone behavior.