AbstractThe effect of interface interaction and processing conditions combined with the viscosity ratio of elastomer domains to the polypropylene (PP) matrix (ηd/ηm, subscript d and m designate the dispersed phase and the matrix, respectively) on fibril formation was investigated. A close to unity viscosity ratio, high interface interaction between the two phases, and a high shear rate in molding were found to result in fibril dispersion. A low‐viscosity elastomer tended to form fibrils also. A high extrusion shear rate seems to have no effect on fibrillar formation, but the dispersion size (Dn) decreased from 0.25 to 0.19 μm with an increasing screw speed from 120 to 160 rpm. The Izod impact strength of blends appears to be optimum when a fine and uniform and nonfibril morphology of the elastomer in PP is formed. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 2085–2092, 2002