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A semi‐empirical expression for predicting phase continuity and inversion in polymer blends and simultaneous interpenetrating networks (SINs) was developed and examined experimentally. A rheological model based on the volume fraction, ϕ, and viscosity, η, led to the equation as the criteria for dual phase continuity for phases 1 and 2. This relation was evaluated for two systems: a castor oil polyester‐urethane/polystyrene SIN, and a mechanical blend of polystyrene and polybutadiene. Literature data was also examined. A gradual phase inversion was found, with a region of dual phase continuity in between. While predictions of phase continuity were confirmed for the mechanical blends, they were not confirmed for the SIN system. This was probably due to rapid gelation at the point of phase inversion.

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One is faced with an interesting challenge when trying to explain the effect of test frequency on polymer fatigue performance. While hysteretic heating arguments appear sufficient to explain a diminution of fatigue resistance with increasing cyclic frequency in unnotched test samples, the enhancement of fatigue resistance in many polymers with increasing cyclic frequency in notched samples is still not clearly understood. In large measure, this is due to contradictory trends in fre‐quency‐sensitive material properties which affect the fatigue process. In this paper, a number of proposed fatigue models dealing with the time and strain rate dependence of elastic modulus, yield strength, creep and localized crack tip heating are examined and confronted with available data from the literature. Additional fatigue crack propagation data for poly(methyl methacrylate), poly (vinyl chloride), polystyrene, poly‐carbonate, nylon 66, poly(vinylidene fluoride) and poly(2,6‐dimethylphenylene oxide) were obtained and are reported herein. These data were obtained over a maximum frequency range of 0.1 to 100 Hz and, for selected polymers, with various waveforms. Frequency sensitivity is shown to be greatest in those polymers that show a high tendency for crazing. Relative fatigue behavior is found to reflect a competition between strain rate and creep effects. Where creep effects dominate, the total crack growth rate may be viewed as consisting of the summation of pure fatigue and creep components, respectively. Finally, the β transition appears to have a role, with frequency sensitivity being at a maximum for polymers where the β transition at room temperature occurs in the range of the experimental test frequency.

Epoxies toughened with two reactive liquid rubbers, an epoxy‐terminated butadiene acrylonitrile rubber (ETBN) and an amino‐terminated butadiene acrylonitrile rubber (ATBN), were prepared and studied in terms of their structure property relationships. A two‐phase structure was formed, consisting of spherical rubber particles dispersed in an epoxy matrix. A broad distribution of rubber particles was observed in all the materials with most of the particles ranging in size from 1 to 4 μm, but some particles exceeding 20 μm were also found. Impact strength, plane strain fracture toughness (KIC), and fracture energy (GIC) were increased, while Young's modulus and yield strength decreased slightly with increasing rubber content and volume fraction of the dispersed phase. Both GIC and KIC were found to increase with increasing apparent molecular weight between crosslinks and decreasing yield strength. The increased size of the plastic zone at the crack tip associated with decreasing yield strength could be the cause of the increased toughness. An ATBN‐toughened system containing the greatest amount of epoxy sub‐inclusion in the rubbery phase demonstrated the best fracture toughness in this series. In the present systems, rubber‐enhanced shear deformation of the matrix is considered to be the major toughening mechanism. Curing conditions and the miscibility between the liquid rubber and the epoxy resin determine the phase morphology of the resulting two‐phase systems. Kerner's equation successfully describes the modulus dependence on volume fraction for the two‐phase epoxy materials.