Effect of material and processing parameters on mechanical properties of Polypropylene/Ethylene–Propylene–Diene–Monomer/clay nanocomposites

Polypropylene/Ethylene–Propylene–Diene–Monomer (PP/EPDM) blends are well known for having a combination of favourable mechanical properties. In this paper, addition of organoclay to PP/EPDM to make PP/EPDM nanocomposites with enhanced mechanical properties is studied. PP/EPDM/organoclay nanocomposites were prepared using a lab scale twin-screw extruder. Maleic anhydride grafted polypropylene (PP-g-MA) was used to enhance the intercalation/exfoliation process and to create good adhesion at the polymer/polymer and polymer/filler interfaces. Taguchi method was employed to deign the experiments and optimize material and processing parameters for optimized mechanical properties. Organoclay (NC) and compatibilizer content were selected as material parameters and the main processing variables were feeding rate and average shear rate (RPM). X-ray diffraction (XRD), Transmission Electron Microscopy (TEM) and Scanning Electron Microscopy (SEM) were used to study the microstructure of the nanocomposites samples. It was observed that NC content and shear rate in extruder improved the tensile strength and modulus. Another important result was the insignificant effect of NC content on impact strength while increasing shear rate first increased and then decreased the impact strength.

► Improved mechanical properties over a broad range of processing conditions.
► Moderate levels of clay and processing parameters lead to higher toughness of TPO.
► Significant improvement of tensile strength and modulus of TPO materials.