The current state of the rheology of various polymeric and other materials containing a high concentration of spherical solid filler is considered. The physics of the critical points on the concentration scale are discussed in detail. These points determine the features of the rheological behavior of the highly filled materials corresponding to transitions from a liquid to a yielding medium, elastic–plastic state, and finally to an elastic solid-like state of suspensions. Theoretical and experimental data are summarized, showing the limits of the most dense packing of solid particles, which is of key importance for applications and obtaining high-quality products. The results of model and fine structural studies of physical phenomena that occur when approaching the point of filling the volume, including the occurrence of instabilities, are considered. The occurrence of heterogeneity in the form of individual clusters is also described. These heterogeneous objects begin to move as a whole that leads to the appearance of discontinuities in the suspension volume or wall slip. Understanding these phenomena is a key for particle technology and multiphase processing.

Powder injection molding (PIM) is one of the modern and prospective technologies in processing different materials. We proposed to use bimodal compositions of particles for increasing their content in the final products. A set of model suspension of Al with low-molecular-weight poly (ethylene glycol) as a binder based on theoretical arguments concerning the filling capacity of bimodal suspensions was prepared. Studying the rheological properties of these compositions showed that they demonstrate elasto-viscous behavior with significant plasticity that is favorable for the technological process. Using compositions with bimodal distributions allows for increasing the content of the solid phase up to 75 vol. % for PIM technology, which is significantly higher than the standard practical limit. This rheological approach developed for model formulations was applied to processing compositions containing aluminum oxide as typical ceramics and polyolefines as a binder widely used in technological practice. The obtained sintered ceramic samples have quite acceptable mechanical properties of the usual corundum articles.

The rheological properties (viscosity, plasticity, viscoelasticity, and elasticity) of noncolloidal suspensions with varying concentrations of a solid phase (Al powder) in oligomeric polyethylene glycol have been studied in the shear mode of deformation. All typical types of rheological behavior have been observed. In the concentration range up to approximately 30%, suspensions are Newtonian liquids, while at a certain concentration, non-Newtonian and viscoelastic effects appear. With further increases in concentration, the flow curves become a power-law type, though the yield stress can be found only for suspensions with a high solid phase content. The elasticity of the suspensions can be detected at concentrations in the order of 55%. In a narrow range of concentrations, the rheological state of the suspensions can be treated as viscoplastic, wherein they preserve fluidity and become elastic. This concentration threshold, determined by the change in various rheological characteristics including the loss tangent, corresponds to the gelation or “colloid” glass transition. The most detailed experiments were devoted to the concentration range of 60–70 vol. %, which are treated as highly concentrated suspensions (HCSs). A concentration of 70% is the upper limit, because mixtures with higher concentrations do not keep their continuity and crumble. The rheological state of HCSs corresponds to the elastoplastic type of behavior. The separation of the total deformation into plastic and elastic components showed that plastic deformations (but not the flow) in the shearing of HCSs are small. Repeated shearing in the loading-unloading mode has been performed. In this case, a decrease in the elastic deformation and a remarkable growth of the shear elastic modulus was observed. This effect is presumably explained by the orientation of the particles and shear-induced anisotropy. A stress-concentration diagram of the physical states of suspensions has been proposed. The concentration range somewhat below that of the HCS state is of special interest for the powder injection molding technology, which is limited by the domain of plasticity.The rheological properties (viscosity, plasticity, viscoelasticity, and elasticity) of noncolloidal suspensions with varying concentrations of a solid phase (Al powder) in oligomeric polyethylene glycol have been studied in the shear mode of deformation. All typical types of rheological behavior have been observed. In the concentration range up to approximately 30%, suspensions are Newtonian liquids, while at a certain concentration, non-Newtonian and viscoelastic effects appear. With further increases in concentration, the flow curves become a power-law type, though the yield stress can be found only for suspensions with a high solid phase content. The elasticity of the suspensions can be detected at concentrations in the order of 55%. In a narrow range of concentrations, the rheological state of the suspensions can be treated as viscoplastic, wherein they preserve fluidity and become elastic. This concentration threshold, determined by the change in various rheological characteristics including the loss...

The molecular characteristics and rheological properties of three UHMWPE samples were investigated. The high-temperature GPC method was used for characterizing UHMWPE samples used. The interpretation of the measurement results was based on calibration using the PS standard and the approximation of the PS data by linear and cubic polynomials, as well as on the data for linear PE. The assessment of the average MW and MWD depends on the choice of calibration method, so that different methods give different results. Only the results obtained using PS with cubic approximation are close to the characteristics offered by the manufacturer. It was also shown that the obtained MW characteristics depend on the dissolution time. The reason for this may be the presence of any processing-aid compounds or destruction of macromolecules. Measurements of the rheological properties were performed in creep modes for a wide range of shear stresses and harmonic oscillations. It was shown that even at 210 °C, UHMWPE does not flow, and the observed irreversible deformations are due to the plasticity of the polymer, i.e., UHMWPE is in an elastic–plastic state. The ultimate plastic deformations drop sharply with increasing MW of the polymer. The plasticity modulus for the highest molecular weight UHMWPE samples does not depend on stress. Measurements of viscoelastic characteristics confirmed that the terminal region of viscous flow cannot be reached under any conditions. Increasing the duration of holding the polymer at high temperature leads not to flow, but to the destruction of macromolecules.

Concentrated metal-in-polymer suspensions (55 vol.% and 60 vol.%) of aluminum powder dispersed in low molecular weight polyethylene glycol) demonstrate elastoplastic properties under compression and shear. The rheological behavior of concentrated suspensions was studied in a rotational rheometer with uniaxial compression (squeezing), as well as shearing superimposed on compression. At a high metal concentration, the elasticity of the material strongly increases under strain, compared with the plasticity. The elastic compression modulus increases with the growth of normal stress. Changes in the shear modulus depend on both normal and shear stresses. At a low compression force, the shear modulus is only slightly dependent on the shear stress. However, high compression stress leads to a decrease in the shear modulus by several orders with the growth of the shear stress. The decrease in the modulus seems to be rather unusual for compacted matter. This phenomenon could be explained by the rearrangement of the specific organization of the suspension under compression, leading to the creation of inhomogeneous structures and their displacement at flow, accompanied by wall slip. The obtained set of rheological characteristics of highly loaded metal-in-polymer suspensions is the basis for understanding the behavior of such systems in the powder injection molding process.

The rheological properties of aluminum suspensions in low-molecular-weight poly(ethylene glycol) have been systematically studied within a wide range of concentrations up to the ultimate...