Fundamental studies on the shear-induced crystallization of PLA and PP with the addition of brown coal

Crystallinity describes the degree of structural order in solids, and in polymers it strongly influences rheological, mechanical, thermal, and optical properties as well as degradation. In this study, we investigate how adding a xylitic brown coal fraction affects the crystallization of polylactide (PLA) and polypropylene (PP) under static and shear conditions. We characterized composites by wide-angle X-ray scattering (WAXS), Fourier transform infrared spectroscopy (FTIR), polarization light microscopy (PLM), scanning electron microscopy (SEM) and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) to examine both crystallization and filler structure. Results show that the lignocellulosic filler markedly alters crystallization kinetics and supramolecular morphology. In PLA-based composites, a transcrystalline layer (TCL) developed at the interface, modifying crystallization and reducing spherulite formation. In PP, only a weak TCL developed due to limited interfacial compatibility. Under shear, PP displayed the expected acceleration of spherulite growth, while PLA showed competing mechanisms between spherulitic nucleation and TCL formation. These findings highlight the role of natural, hybrid organic–mineral fillers in tailoring polymer crystallization processes and improving composite design.