Katsuhiko
Tsunoda
*a,
Yuji
Kitamura
b and
Kenji
Urayama
*c
aSustainable and Advanced Materials Division, Bridgestone Corporation, Tokyo 187-8531, Japan. E-mail: katsuhiko.tsunoda@bridgestone.com
bSustainable and Advanced Materials Division, Bridgestone Corporation, Tokyo 187-8531, Japan
cDepartment of Material Chemistry, Graduate School of Engineering, Kyoto University, Kyoto 615-8510, Japan. E-mail: urayama.kenji.2s@kyoto-u.ac.jp
First published on 22nd February 2023
We revisit the classical results that the fracture energy density (Wb) of strain crystallizing (SC) elastomers exhibits an abrupt change at a characteristic value () of initial notch length (c0) in tensile edge-crack tests. We elucidate that the abrupt change of Wb reflects the transition in rupture mode between the catastrophic crack growth without a significant SIC effect at c0 > and the crack growth like that under cyclic loading (dc/dn mode) at c0 < as a result of a pronounced SIC effect near the crack tip. At c0 < , the tearing energy (G) was considerably enhanced by hardening via SIC near the crack tip, preventing and postponing catastrophic crack growth. The fracture dominated by the dc/dn mode at c0 < was validated by the c0-dependent G characterized by G = (c0/B)1/2/2 and the specific striations on the fracture surface. As the theory expects, coefficient B quantitatively agreed with the result of a separate cyclic loading test using the same specimen. We propose the methodology to quantify the tearing energy enhanced via SIC (GSIC) and to evaluate the dependence of GSIC on ambient temperature (T) and strain rate (). The disappearance of the transition feature in the Wb–c0 relationships enables us to estimate definitely the upper limits of the SIC effects for T (T*) and (*). Comparisons of the GSIC, T*, and * values between natural rubber (NR) and its synthetic analog reveal the superior reinforcement effect via SIC in NR.
The SIC near the crack tip subjected to large deformation contributes to enhancing the tear strength or suppressing the catastrophic crack growth.15–20 The SIC near the crack tip was revealed by investigations using the micro-beam wide-angle X-ray scattering (WAXS) technique.21,22 However, many aspects of the reinforcement effects via SIC remain to be quantified. The reinforcement effect via SIC is expected to have an upper limit for each ambient temperature (T) and imposed strain rate () (designated as T* and *, respectively), because the crystal has a melting temperature and SIC is a kinetic event. The melting temperatures (Tf) of the SIC crystals of NR and IR were investigated using WAXS experiments in the stretched state at various T.23–29 The Tf increased with imposed stretch reflecting an increase in the crystallinity index, which was thermodynamically explained by a reduction in the configurational entropy of network strands.1–3,30Tf is an equilibrium property, while the SIC kinetics is significantly affected by the ambient temperature (T). At T* the SIC kinetics becomes so slow that SIC cannot occur at of interest.
The effect of on SIC was examined by WAXS experiments using custom-made tensile instruments that could achieve high strain rates. The upper limit for SIC remains unclear because finite SIC was still observed at high strain rates on the order of 102 s−1.31–35 The reinforcement effect via SIC is expected to depend on T and and to disappear at sufficiently high T or exceeding T* and *. However, in general, the evaluations of T* and * in conventional tensile tests using unnotched bulk specimens involve appreciable ambiguity, because the tensile strength (stress at break) data as a function of T or often show scattering owing to the high susceptibility to inherent flaws.36
The evaluation of the tearing energy, which is the energy required for crack propagation at given T and , in rubber-like materials has attracted considerable interest since tearing energy is a key property to characterize the fracture behavior.37–45 A classical tensile fracture test, called the “edge-crack test,” provides an important basis for characterizing the reinforcement effect via SIC.36,46–48 Thomas et al.36,46,47 and Hamed et al.48 investigated the strain energy density at break (Wb) for pre-notched NR specimens as a function of the initial notch length (c0) through tensile experiments. They found that Wb decreased with increasing c0, but with an abrupt fall at a characteristic c0 value (), whereas this abrupt change was not observed for non-SIC rubber. They regarded this discontinuity as a transition between the tensile fractures with or without a significant SIC effect; at c0 < , a sufficiently wide region near the crack tip underwent SIC, resulting in an enhancement of Wb. Hamed et al. investigated the influence of cross-links and filler contents on the transition behavior of NR in edge-crack tests49,50 and discussed the synergetic effects of SIC and filler loading.
In this study, we revisit the discontinuous Wb–c0 relationships specific to the SIC rubbers and elucidate that the discontinuity results from the transition of rupture mode between the catastrophic crack growth without an appreciable SIC effect at c0 > and the crack growth like that under cyclic loading (dc/dn mode) undergoing a significant SIC effect. The occurrence of the cyclic crack growth mode at c0 < is validated by the characteristic striations on the fracture surface and the result of a separate cyclic loading test using the same specimen. We propose the methodology to quantify the tearing energy enhanced via SIC (GSIC) from the Wb–c0 data and to evaluate T* and * from the disappearance of the transition feature. We demonstrate that the comparisons of the GSIC, T*, and * values between NR and IR reveal the superior reinforcement effect via SIC in NR.
(1) |
G = 2kWc | (2) |
Eqn (2) was experimentally validated using the edge-crack test of non-SIC rubbers by varying the initial notch length (c0):52 the strain energy density at break (Wb) is simply proportional to c0−1, reflecting the fact that G is a material constant for non-SIC rubbers. By contrast, SIC rubbers exhibit a discontinuous transition in the Wb–c0 relationships: Wb decreases with increasing c0, and notably, Wb falls abruptly at a characteristic value of c0 (),36,46–48 which is schematically shown in Fig. 1a. Thomas et al.36,46,47 regarded this abrupt change in Wb at as a transition in the rupture mechanism; at c0 > , no significant SIC occurs ahead of the advancing crack tip of the specimens, resulting in the catastrophic crack growth process observed in the non-SIC rubbers. At c0 < , a sufficiently large SIC region emerged near the crack tip, preventing or postponing the catastrophic crack growth process. At c0 > without a significant SIC effect, when the failure follows the ordinary tearing mode, the c0 dependence of Wb can be expressed by eqn (2) as follows:
(3) |
G = 2kW(c0 + Δc) | (4) |
Δc = BG2 | (5) |
Δc = 4k2B (c0 + Δc)2W2 | (6) |
(7) |
The Wb values below are significantly larger than those beyond , reflecting the enhancement effect of SIC on the tearing energy. However, the corresponding effect is yet to be quantified from the Wb–c0 data. Therefore, we extend the analysis to quantify the tearing energy enhanced by the SIC effect (GSIC). Eqn (4) is expressed using eqn (7) by eliminating k as follows:
(8) |
Investigations of the Wb–c0 relationships with varying ambient temperatures (T) and strain rates () (Fig. 1a) provide a basis for discussing the effects of T and on GSIC. In particular, the corresponding data also enable us to evaluate T* and * (the upper limits for the SIC effect on tearing energy) because at T > T* and > *, the transition feature vanishes, and only the ordinary tearing mode (G ≈ GT; eqn (3)) appears over the entire c0 range.
First, gum, stearic acid, ZnO, TMQD, and 6PPD were mixed, and the mixture was sheared for 2 min in a chamber at a controlled temperature of 80 °C. Next, CBS and sulfur were added for vulcanization, and the mixtures were subjected to shear for 1.5 min at 80 °C. The mixtures were further sheared using an open-roll mill for 5 min at 60 °C. Finally, specimen sheets were prepared using a hot press method at 160 °C for 8 and 13 min for NR and IR, respectively. We used the NR-A and IR-A specimens for the edge-crack tests in order to investigate the enhancement effects via SIC on tearing energy at various T and values.
For comparing the results of the edge-crack and the cyclic loading tests, we employed the NR-B specimen which had almost the same compositions as NR-A but slightly differed in curatives: 1,3-diphenylguanidine (DPG, 0.35 phr), N-cyclohexyl-2-benzothiazole sulfenamide (CBS, 1.77 phr) and sulfur (1.4 phr). The processing procedure for the sheet specimens of NR-B was the same as that for NR-A.
NR-A and IR-A exhibited the same magnitudes of equilibrium swelling in toluene within the experimental error, indicating that they have similar cross-link densities. The average molecular weights between neighboring cross-links were estimated to be 7200 g mol−1 for NR-A and IR-A and 6400 g mol−1 for NR-B from the equilibrium swelling degrees using the Flory–Rehner equation.55
A styrene butadiene rubber (SBR) specimen was prepared as a non-SIC rubber for comparison, using SBR gum (#1500, ENEOS Material Co.). The compositions of stearic acid, ZnO, TMQD, 6PPD and sulfur were identical to those of NR-A. Diphenyl guanidine (1 phr), 2-benzothiazolyl disulfide (0.6 phr), and N-oxydiethylene-2-benzothiazole sulfenamide (0.6 phr) were used as cure accelerators. The specimen sheets were made using the same method as for NR-A at 160 °C for 6 min.
The tensile force at break (fb) of a pre-notched specimen with an initial notch length (c0) was measured under the given conditions of T and . The tearing energy (G) was calculated using eqn (2) corresponding to eqn (4) with Δc/c0 ≪ 1. The strain energy density at break (Wb) and λ in eqn (2) were obtained with the fb value using the W–σ and σ–λ relationships for the corresponding unnotched bulk specimen.
Ix(q, λ) = IOBSx (q, λ) − IOBSx (q, λ < 2) | (9) |
Fig. 2 (a) Strain energy density at break (Wb) as a function of the initial notch length (c0) for SBR (non-SIC rubber) at 25 °C and a strain rate of 0.60 s−1 in the edge-crack test. (b) The c0 dependence of tearing energy (G) calculated using the data in (a) with eqn (2). |
Fig. 3 (a) Strain energy density at break (Wb) as a function of the initial notch length (c0) for NR-B at 25 °C and a strain rate of 0.11 s−1 in the edge-crack test. (b) The c0 dependence of tearing energy (G) calculated using the data in (a) with eqn (2). The dashed line indicates the position of at which an abrupt change occurs. The solid line represents the fitted curve of eqn (8) to the data using B = 3.65 × 10−13 N−2 m3. The dashed solid line depicts the curve of eqn (8) with the B value (4.06 × 10−13 N−2 m3) obtained using the cyclic loading test for the same specimen. (c) Increment of crack length (Δc) as a function of 4k2B (c0 + Δc)2W2 for NR-B in the cyclic loading test. The line indicates the result of the linear regression. The slope corresponds to the B value (4.06 × 10−13 N−2 m3). (d) Fracture surfaces for NR-B of c0 = 0.29 mm (<) and c0 = 2.23 mm (>). For c0 = 0.29 mm, the fine striation lines characteristic of the crack growth via the dc/dn mode are observed. The zone “c0” indicates the initial notch area. (e) Fracture surfaces including the striations for NR-B in the cyclic loading test. |
The different rupture modes at c0 > and c0 < are also appreciable when comparing the fracture surfaces of the corresponding specimens, as shown in Fig. 3d. The fracture surface of the edge-crack specimen with c0 = 0.29 mm (<) has characteristic marks (fine striation lines) that show the positions of the crack tip during the incremental growth of a crack. Similar striations are observed in the failure surfaces of NR in the cyclic fatigue tests,19,20 and Fig. 3e shows the striations accompanied by the sub-striations in the failure surface of NR-B in the cyclic loading tests. As the corresponding features are not observed in the non-SIC rubbers, they are attributed to SIC.19,20 The fracture surface of the edge-crack specimen of c0 = 2.23 mm (>) has no indication of striation (Fig. 3d). The fracture surface including the striations at c0 < in the edge-crack tests indicates that SIC postpones the catastrophic crack growth.
The successful fit of eqn (8) to the G–c0 data using the B value obtained by the cyclic loading test (Fig. 3b) and the striation characteristic of the cyclic crack growth (Fig. 3d) validate the theoretical interpretation of the data described in the previous section. The considerably different G–c0 relationships beyond and above are attributed to a transition of the rupture mode. The rupture at c0 > without significant SIC near the crack tip is governed by the ordinary tear mode. At c0 < , the crack grows through a sufficiently large crystalline region, and the corresponding fracture proceeds similarly to the crack growth under cyclic loading, characterized by eqn (8). The maximum G value at in Fig. 3b is considered a measure of the tearing energy enhanced by SIC (GSIC). The quasi-plateau G value at c0 > is regarded as a critical tearing energy for the onset of catastrophic crack growth without the SIC effect (GT). In Fig. 3b, the GSIC is evaluated to be 33 kJ m−2, while the GT is estimated to be 10 kJ m−2 from the average of the data at c0 > .
Fig. 4 (a) Strain energy density at break (Wb) as a function of the initial notch length (c0) at various ambient temperatures (T) for NR-A at a strain rate of 0.5 s−1. (b) The c0 dependence of tearing energy (G) calculated using the data in (a) with eqn (2). The dashed lines indicate the position of at which an abrupt change occurs for each T. No abrupt change is observed at 90 °C. |
Fig. 5 (a) Strain energy density at break (Wb) as a function of the initial notch length (c0) at various ambient temperatures (T) for IR-A at a strain rate of 0.5 s−1. (b) The c0 dependence of tearing energy (G) calculated using the data in (a) with eqn (2). The dashed lines indicate the position of at which an abrupt change occurs for each T. No abrupt change is observed at T ≥ 70 °C. |
The G vs. c0 plots obtained using eqn (2) and the data in Fig. 4a and 5a are shown in Fig. 4b and 5b, respectively. At T < T*, the G values have the maximum at , allowing the evaluation of the GSIC at each T. GSIC tends to decrease with increasing T in both NR and IR. At T > T*, only GT is obtained, reflecting the absence of an appreciable SIC effect. In contrast to GSIC, GT is almost independent of T at T ≥ 45 °C. Thus, this method reveals the upper limit temperature (T*), beyond which the effect of SIC on tearing energy vanishes, and the T-dependence of GSIC. The G data in the vicinity of at c0 > in T < T* tend to be larger than the GT value obtained at a high c0. This tendency implies that a subtle degree of the SIC effect may exist at c0 slightly beyond although most of the effect vanishes when c0 exceeds .
Fig. 6 shows the plots of GSIC and GT obtained in Fig. 4b and 5b against T for NR-A and IR-A. The GT values are nearly insensitive to T, except for the data at 25 °C, and there is no appreciable difference between these two rubbers. In contrast, for each rubber, the GSIC value at a given T is several times larger than GT, whereas GSIC decreases with increasing T. These results indicate that G is significantly enhanced by hardening via SIC near the crack tip, whereas this reinforcement effect decreases with a decreasing crystallinity index. Notably, these two rubbers are considerably different in T* and GSIC; T* for NR-A (80 °C) is approximately 20 °C higher than that for IR-A (60 °C), indicating that the reinforcement effect in NR emerges in a broader temperature range. Furthermore, the GSIC value for NR at each T is significantly larger than that for IR.
The effects of T on SIC are separately investigated using WAXS experiments using unnotched bulk NR-A and IR-A specimens. Fig. 7a and b show the peak area of the crystal (200) diffraction (I200) as a function of tensile strain at various T values. The evolution of I200 beyond the threshold strain reflects a continuous increase in the crystallinity index via SIC. The SIC onset strain (εSIC) was estimated from the onset of the evolution of I200. For both rubbers, as T increases, εSIC increases, and I200 decreases when compared at a given strain. At a sufficiently high T, I200 remains zero over the entire strain range, indicating no occurrence of SIC; SIC can no longer be observed even at a high strain at 110 and 80 °C for NR-A and IR-A, respectively, which explains no occurrence of significant SIC at the crack tip in the edge-crack specimens at T > T*. The upper-limit temperature for SIC (), the highest temperature for the finite evolution of I200, is evaluated to be 90 and 70 °C for NR-A and IR-A, respectively. The for NR-A is approximately 20 °C higher than that for IR-A, which is comparable to the difference in T* (Fig. 6). This agreement validates the evaluation of T* as the upper-limit ambient temperature in edge-crack tests. For each rubber, T* is slightly lower than , probably because of the finite difference in the magnitudes of the effective strain and strain rate in the two measurements; the local strain and strain rate around the crack tip are higher than those in the tensile test of the unnotched bulk specimens. In addition, detects the threshold of SIC at the molecular level, while T* reflects the threshold of the SIC effect on macroscopic tearing energy. The emergence of the SIC effect on bulk mechanical properties requires a finite degree of crystallization. This also explains the relationship of > T* for each rubber.
Fig. 7 Scattering intensity of the (200) diffraction of the SIC crystal as a function of the imposed tensile strain for (a) NR-A and (b) IR-A at various ambient temperatures. |
In each rubber, I200 decreases with increasing T when compared at the same strain, indicating that the crystallinity index at a given strain decreases as T increases. This result explains why the GSIC decreases with increasing T for each rubber (Fig. 6).
The effects of T on the SIC for NR and IR have been studied using in-situ WAXS experiments, mainly in the sustained state with a constant strain beyond εSIC or by analyzing the stress–strain relationships.23–29 The reported values of the melting temperature of the SIC crystal (Tf) of IR range from 60 to more than 100 °C depending on the magnitude of the imposed constant strain. The value (70 °C) for IR-A falls within the range of the reported values.
Fig. 8 (a) Strain energy density at break (Wb) as a function of the initial notch length (c0) at various strain rates () for NR-A at 25 °C. (b) The c0 dependence of tearing energy (G) calculated using the data in (a) with eqn (2). The dashed lines indicate the position of at which an abrupt change occurs for each . No abrupt change is observed at 500 s−1. |
Fig. 9 (a) Strain energy density at break (Wb) as a function of the initial notch length (c0) at various strain rates () for IR-A at 25 °C. (b) The c0 dependence of tearing energy (G) calculated using the data in (a) with eqn (2). The dashed lines indicate the position of at which an abrupt change occurs for each . No abrupt change is observed at > 5 s−1. |
Fig. 10 shows the plots of GSIC and GT against for NR-A and IR-A. An appreciable reinforcement of SIC on tearing energy (GSIC > GT) is observed at < *, while it vanishes at > *. At > *, the imposed strain rate is so high that the matrix around the crack tip cannot have enough time to undergo a sufficient degree of SIC, resulting in a catastrophic fracture governed by the GT. As this result originates from the competition between the SIC and strain rate, *depends on T of interest. For convenience, we regard the * from the highest value at which finite discontinuity is observed in the G–c0 relationship because the data as a function of are discrete. Notably, the * value for NR-A (50 s−1) is considerably higher than that for IR-A (0.5 s−1). There exists some uncertainty in the * value for IR-A because of the ambiguity of the discontinuous feature in the data at 5 s−1: Finite discontinuity is appreciable in Wb (Fig. 9a) but not in G (Fig. 9b). The * value for IR-A may be slightly higher than 0.5 s−1. Nevertheless, we can conclude safely that * for NR-A is at least one order of magnitude higher than that for IR-A because of a definite difference in the discontinuity in the data at 50 s−1 between them. In addition, the GSIC for NR-A is larger than that for IR-A when compared at the same . As in the case of the T effect (Fig. 6), the finite superiority of NR relative to IR in reinforcing ability via SIC is appreciable in the effect of .
Several researchers have studied the effect of on SIC for NR or IR using in situ WAXS experiments.31–35 Recently, Kitamura et al.35 showed that the times required for the occurrence of finite SIC in NR and IR were comparable and less than 0.01 s. Candau et al.34 also reported that the finite superiority of NR relative to IR in SIC ability (observed at slow strain rates) disappeared at high strain rates. According to their results, the occurrence of finite SIC and the disappearance of the difference in the reinforcement effect between NR and IR are expected at high strain rates of more than 100 s−1. However, the * values (50 s−1 for NR-A and 0.5 s−1 for IR-A) in the edge-crack tests are appreciably lower than this expectation, and they were considerably different between NR-A and IR-A. These discrepancies indicate that the threshold for the emergence of the SIC effect on the macroscopic mechanical strength (reflected in the edge crack tests) is different from the onset of SIC at the molecular level (detected by WAXS): the onset of the finite mechanical reinforcement effect requires a significant degree of crystallization. It should also be noted that the magnitudes of local strain and strain-rate near the crack tip are considerably larger than those in the unnotched bulk materials used in the WAXS measurements, when compared at the same degree of imposed macroscopic strain.
The maximum G value at , calculated from the Wb–c0 data by extending Thomas’ theory, is regarded as a measure of the tearing energy enhanced by SIC (GSIC). The magnitude of the GSIC is several times larger than that of the GT, reflecting that the crack propagates through the matrix hardened by crystallization. The GSIC values decrease with increasing T and due to a reduction in the crystallinity index. The upper limits of T and for the finite reinforcement effect via SIC (T* and *, respectively) are evaluated from the vanishing points of the transition feature.
NR exhibits a higher magnitude of GSIC at a given T or than IR, whereas these rubbers show no appreciable difference in GT. NR has an approximately 20 °C higher value of T* and at least one order of magnitude larger value of * than IR. The WAXS measurements confirm a reduction in the crystallinity index with increasing T and an approximately 20 °C higher upper-limit temperature for the occurrence of SIC in NR. Comparisons using the GSIC, T*, and * values reveal that NR is obviously superior to IR in the mechanical reinforcement effect via SIC.
Footnote |
† Electronic supplementary information (ESI) available: Tensile force–displacement curves for NR-B with various c0 values at 25 °C with a strain rate of 0.11 s−1 in the edge-crack test. See DOI: https://doi.org/10.1039/d3sm00060e |
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