The present study deals with the consolidation of an ultra‐high performance polymer, the poly(ether ether ketone) (PEEK), for structural applications, using the powder metallurgy (PM) way, and more precisely the Spark Plasma Sintering (SPS) processing. The effects of SPS parameters such as temperature, pressure, and dwell time on density and mechanical properties of PEEK were investigated via a Design of Experiments (DoE). A temperature of 250 °C, a pressure of 40 MPa, and a dwell time of 20 min have been identified as the optimal SPS process parameters. In these conditions, a density of 1.31 g/cm3 was reached and homogeneous mechanical properties in the volume determined by means of compression tests were found with a compressive modulus of 2.75 GPa, a yield strength of 134 MPa, and a maximum compressive strain of 43%. These results are better than those of commercial products obtained by injection molding. The pressure appears to be a significant parameter on PEEK properties and plays positive or negative roles according to the responses of DoE studied. To our knowledge, it is one of the first studies based on the application of the PM techniques for PEEK consolidation showing the possibility to process below its melting point. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017, 134, 44911.
This study deals with the understanding of the sintering mechanisms that occur during consolidation of an ultra-highperformance polymer: poly (ether-ether-ketone). In particular, we investigated the effects of uniaxial pressure during spark plasma sintering (SPS) processing. Glass-transition temperature (T g ) measurements under loading, stress-strain curves and scanning electron microscopy analysis allowed us to determine the role of pressure intensity and temperature of application on macromolecular chain mobility in both the bulk and the surface of the particles. First, a loss of chain mobility in the bulk of the particles was observed under high pressure. Second, it was shown that high pressure applied at low temperature leads to friction effects between the particles which enhances chain mobility in the particle shell through a local melting phenomenon. These experimental conditions favor the healing of particles and high cohesion was then observed in the resulting sintered samples. The level of friction is enhanced when pressure is applied at a low temperature since the powders are still in a glassy state. Finally, the achievement of cohesive grain boundaries was found to be related to the location and conformation of chain ends. Good healing between particles can only occur if a sufficient number of chain ends are available at the surface of the particle shell. We showed that the native powder state plays a significant role. The direct use of as-received powder leads to final material exhibiting good cohesion whereas pretreatments of the native powder are highly detrimental. It should be noted that this processing does not affect the high initial degree of crystallinity because no bulk melting is observed during consolidation by sintering.
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