Ductile-to-brittle transition in cenosphere-filled polypropylene composites

Cenosphere-filled polypropylene (PP) composites were fabricated and characterized for their structural/morphological and fracture mechanical behaviour. The fracture properties were studied following the essential work of fracture (EWF) approach based on post-yield fracture mechanics (PYFM) concept. The structural attributes and its consequent effects on the dynamic mechanical properties were characterized by wide angle X-ray diffraction (WAXD), hot-stage polarized light optical microscopy (PLOM) and dynamic mechanical analysis (DMA). The WAXD studies have revealed a decrease in crystallinity of the composites with increase in cenosphere content. PLOM studies reveals a threefold reduction in the diameter of the spherulite in case of composite with 10 wt% of cenosphere compared to that of PP followed by an increase of ~50% in the composite with 20 wt% of cenosphere compared to that of the composite with 10 wt% cenosphere. DMA revealed an enhancement in the energy dissipation ability of the composite with 10 wt% of cenosphere and an increase in the storage modulus up to ~30% in the composites relative to the soft PP phase. The non-essential work of fracture (NEWF: βw p) as the resistance to stable crack propagation has shown a maximum at 10 wt% of cenosphere followed by a sharp drop at higher cenosphere content indicating a cenosphere-induced ductile-to-brittle transition (DBT). Fractured surface morphology investigations revealed that the failure mode of the composites undergo a systematic transition from matrix-controlled shear deformation to filler-controlled quasi-brittle modes above a cenosphere loading of 10 wt% in the composites reiterating the possibility of filler-induced semiductile-to-DBT transition.