ABSTRACT:In this paper, we investigate the relationships between the viscosity ratio, morphology, and processing temperature of composite fibers comprising liquid crystalline polymer (LCP) and polyamide-66 (PA 66). Furthermore, we examine in details the effect of the LCP concentration on the phase microstructure and the mechanical properties of the composite fibers. The results show that, first, the optimal processing temperature of melt spinning of the composite fibers depends strongly on the viscosity ratio of LCP to PA 66 though the processing temperature range can be determined by the degradation temperature of PA 66 and the melting point of LCP. Secondly, the LCP phase structure/morphology in composite fibers can be controlled by the viscosity ratio of LCP to PA 66. Thirdly, the LCP phase structure/morphology are changed with LCP concentration for a fixed viscosity ratio/processing temperature. With an increase in LCP concentration, the morphology of LCP phase is changed from a fine fibril dispersed phase to a perfectly aligned continuous fiber reinforced phase in a rich LCP composite fiber. Finally, the mechanical properties of LCP composite fibers depend on the LCP phase structure/morphology and LCP concentration. The tensile properties of the composite fibers exhibit the positive synergy in the rich LCP composite fibers.KEY WORDS Composite Fibers / Morphology Control / Viscosity Ratio / Processing Temperature / Liquid Crystalline Polymer (LCP) Concentration / Mechanical Properties / The morphology of the materials, especially the morphology/microstructure of the LCP phase, has a strong influence on the mechanical properties of the composite materials comprising thermotropic liquid crystalline polymers (LCPs) and thermoplastic matrix. In general, the thermotropic LCPs do not directly transform to an isotropic melt when heated above their melting point, but to a state where the orientational long-range order is preserved whereas the long-range positional order breaks down. Thermotropic LCPs are essentially rigid-rod long-chain molecules with some irregularity or flexibility incorporated into the polymer chain to lower the melting point below the decomposition temperature. The rigid-rod molecular structure allows these materials to exhibit molecular order in a liquid mesophase. The highly oriented nature of LCPs produces highly anisotropic physical property and makes thermotropic LCPs quite attractive as a potential dispersed phase in in-situ reinforcing materials. The processing conditions affect the morphology and properties of the composites significantly. The processing conditions are also related to rheological properties of polymers, which determine the deformation and flow behavior of polymer materials in liquid, melt or solid form. In many industrial processes, polymer melts are subject to complex flows and temperature histories. To understand these complex flows, the response of the polymer melts in simple flow fields has been studied to determine material properties such as the viscosity, normal ...