Ultra-high molecular weight polyethylene (UHMWPE) and high-density polyethylene (HDPE) blend fibers with the highest tensile strength of 1.13 GPa were prepared by a melt spinning process. The mechanical behavior and crystal structure of the as-spun filaments and fibers were studied by differential scanning calorimetry (DSC), scanning electron microscopy (SEM), X-ray diffraction (XRD), sound velocity orientation testing, and tensile testing. The orientation degree, crystallinity, tensile strength, and initial modulus of the fibers increased with the increasing of the draw ratios. The grain size was shortened in the radial direction and elongated in the axial direction. The results suggested that the improvement of the tensile strength and initial modulus was a result of the compact crystal structure formed by slender grains composed of highly oriented molecular chains. Blending with HDPE could improve the formation of a slender and compact crystal structure, and the tensile strength and initial modulus of the blend fibers were higher.

The influence of spinning temperature on ultrahigh-molecular-weight polyethylene/high-density polyethylene as-spun blend filaments and the influence of drawing temperature on ultrahigh-molecular-weight polyethylene/high-density polyethylene-blend fibers were investigated. The results showed that the optimum spinning and hot-drawing temperatures were 310℃ and 85℃, respectively, and blending with high-density polyethylene improved the orienting ability of the molecular chains and the crystallization ability. The blend filaments spun at 310℃ had the best molecular chain orientation, crystallinity and crystal orientation of the filaments examined; both lower and higher spinning temperatures were detrimental to the crystal structure growth of the as-spun blend filaments. The optimum drawing temperature of the blend fibers was 85℃, which resulted in blend fibers with the best molecular chain orientation, crystallization, and crystal orientation as well as the thinnest grains of the fibers examined. The highest tensile strength and initial modulus were 1204 MPa and 20.4 GPa, respectively; these high values can be attributed to the fibrillar structure, which consisted of extended molecular chains and thin grains. The results in this paper can help disclose the effect mechanism of formation temperature on the melt spinning method used to produce high-strength ultrahigh-molecular-weight polyethylene fibers.

High-density polyethylene (HDPE) content significantly influences the structure and mechanical properties of ultrahigh molecular weight polyethylene (UHMWPE)/HDPE blend fibers. The molecular chain disentanglement and crystallization characteristics of as-spun filaments and fibers and how the structure affects the final mechanical properties of the fibers were thoroughly studied by adding different contents of HDPE. Dynamic mechanical analysis (DMA) and rheological analysis indicated that the molecular entanglement decreased with increasing HDPE content, improving the UHMWPE melt processability. Sound velocity orientation (SVO) studies indicated that the UHMWPE/HDPE as-spun filaments and fibers with an HDPE content of 40 wt% (U6H4) had a higher molecular chain orientation level. Furthermore, differential scanning calorimetry (DSC) and wide-angle X-ray diffraction (WAXD) analyses indicated that U6H4 had the highest crystallinity and the thinnest grains in the axial direction, respectively. The compact crystal structure and fully stretched molecular chains of U6H4 yielded the best mechanical properties. The present work disclosed the effect mechanism of HDPE contents on the preparation and properties of UHMWPE/HDPE fibers, which provided an effective and universal strategy for manufacturing high-strength UHMWPE/HDPE fibers with the melt spinning method.

This study investigates the influence of cooling rates on the structural evolution and mechanical properties of ultra-high-molecular-weight polyethylene/high-density polyethylene fibers by systematically varying cooling media from ambient air (f1) to room-temperature water (f5). A significant structural inversion was observed between the as-spun and drawn fiber stages: while slow cooling (f1) promotes thermodynamic crystallization to form large, stable grains and maximum initial crystallinity (54%), rapid quenching (f5) effectively “freezes” the molecular chains in a low-crystallinity, highly orientable precursor state by suppressing thermal relaxation. During subsequent hot-drawing, the quenched samples (f5) exhibited a superior response to tensile stress, achieving the highest maximum draw ratio due to reduced crystalline obstacles and enhanced chain mobility. This enables efficient stress-induced crystallization, leading to near-perfect crystal orientation (f_c > 0.95) and a dense microfibrillar framework. Consequently, the fiber performance trends reversed, with f5 achieving peak tensile strength (1.33 GPa) and modulus, whereas f1 remained limited by its rigid thermal history. These findings highlight that rapid quenching is essential for developing high-performance fibers by preserving a precursor structure that maximizes the potential of stress-induced crystallization.