An experimental study of the development of phase morphology in incompatible polymer melt blends of polyethylene/polystyrene (PE/PS), polyethylene/polycarbonate (PE/PC), and polyethylene/nylon‐6 (PE/N6) is presented. Different temperatures (180°C, 240°C) of mixing and polyethylene molecular‐ weight levels were used in the PE/PS studies. Little variation in the cross‐sectional phase morphology of the PE/PS extrudates was observed with these variables, though the morphology became finer with increased shear rate/stress in capillary die flow. Variations in the longitudinal morphology are observed with continuous filaments of dispersed phase only arising when the dispersed phase has an equal or lower viscosity than the continuous phase. The PE/N6 and PE/PC, especially the former, give coarser morphologies when the N6 and PC are the continuous phases. This was attributed to larger inter‐facial tensions. The effect of viscoelasticity was also discussed.
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Min et al. (1984) studied this question.