Nascent powders of ultrahigh molecular weight polyethylene (UHMWPE) with different molecular weights in the range 0.6 < M v < 10.5 million g/mol have been processed by means of sintering. The interface consolidation or particle welding was carried out under pressure at various temperatures above the melting point and for various durations. Tensile drawing experiments performed above the melting point enabled to study the role of chain interdiffusion through the particle interface. The melting explosion phenomenon was demonstrated to occur for each molecular weight. The higher is M v , the greater is the efficiency of the phenomenon. But this does not allow a homogenization of the entanglement network of the sintered sample. Indeed, heterogeneity of deformation between the grain and the interface clearly appears during tensile tests above the melting temperature. The differences in mechanical behavior in the molten state between the molecular weights seem exacerbated by crystallization under tension. After melting explosion, end-chain diffusion as well as sideways motions are probably involved in the healing of very long chains polymer interfaces to reach a sufficiently high entanglement density. This latter phenomenon seems thermally activated.
■ INTRODUCTIONOne of the main issues of processing ultrahigh molecular weight polyethylene (UHMWPE) is to overcome its very high viscosity that precludes conventional melt processing such as injection or extrusion. As a consequence, a method inspired from powder metallurgy, sintering, has been developed. The polymer sintering is generally separated in three steps: 2 densification corresponding to wetting between grain, then chain diffusion across interfaces, and finally crystallization for semicrystalline polymer. This three-step separation was therefore adopted in the protocol of sintering. However, sintering mechanisms of polymer materials remain incompletely understood.In the case of sintering of semicrystalline polymers, two phenomena have been identified: (i) Chain diffusion across the interfaces of adjacent grains allowing the reentanglement of polymer chains was studied in particular in the case of amorphous polymer. 1,2 (ii) Cocrystallization, corresponding to the strengthening of the interfaces by crystallization involving chains from the adjacent grains. 3−7The diffusion of long chain polymers in the rubbery state is generally described by the reptation theory. 8,9 Moreover, it has been shown that the degree of chain disentanglement of UHMWPE nascent powders may significantly differ depending on the synthesis method so that reentanglement may be a slow and heterogeneous process. The heterogeneity of the entanglement network has consequences on the mechanical properties of both molten and semicrystalline states of the materials. 10−12 Finally, it has been shown that another phenomenon enables chain diffusion and reentanglement in much shorter time than reptation. 13−16 This phenomenon has been given evidence by molding or welding of disentangled solution-crystal...