Worm melt fracture and fast die build-up at high shear rates in extrusion blow molding of large drums

Abstract

In the extrusion blow molding process of high density polyethylene (HDPE) for making of large size drums, string-like defects, which are referred to as worm melt fracture in the industry, are often observed on the extrudate surface. Such string-like defects in various shapes and sizes are observed in capillary extrusion at very high shear rates after the slip-stick transition. The HDPE resin with broader molecular weight distribution (MWD) exhibits a greater degree of worm melt fracture while the narrow MWD PE resin, which has higher slip velocity and a uniform slip layer, shows a lesser degree of worm melt fracture. It is hypothesized that the worm melt fracture is related to fast die build-up and cohesive slip layer, a failure within the polymer melts at an internal surface. If the cohesive slip layer at an internal surface emerges out from the die, it can be attached on the surface of extrudate as string-like defects, the worm melt fracture. The resin having more small chains and lower plateau modulus can be easier to have such an internal failure and consequently exhibit more “worm” defects.