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In this study, the hierarchical crystalline structures of high-density polyethylene (HDPE) samples molded by gas-assisted injection molding (GAIM) with different gas cooling times were characterized via scanning electron microscopy, two-dimensional wide-angle X-ray scattering, tensile testing techniques, and differential scanning calorimetry, respectively. It was found that the shish-kebab, the oriented lamellae, and common spherulite structures orderly distributed from the skin region to gas channel region of samples. More importantly, the wider area with highly oriented structure (shish-kebab) was obtained in the samples with longer gas cooling time, in that the longer gas cooling time tends to increase the cooling rate of polymer melt, and then much more stretched chains are retained. Although lower crystallinity, the higher degree of orientation, and much more shish-kebab structures lead to significant reinforcement from 28 to 785 MPa of the samples with gas cooling time of 0.5 s to 32 and 879 MPa of the samples with gas cooling time of 20 s for tensile strength and modulus, respectively. Finally, combined the HDPE molecular parameter with characteristic of the GAIM temperature field and flow field, the formation and stability of crystalline morphology in different regions of sample were discussed. [ABSTRACT FROM AUTHOR]

The hierarchy structures and orientation behavior of high-density polyethylene (HDPE) molded by conventional injection molding (CIM) and gas-assisted injection molding (GAIM) were intensively examined by using scanning electronic microscopy (SEM) and 2D wide-angle X-ray diffraction (2D-WAXD). Results show that the spatial variation of crystals across the thickness of sample molded by CIM was characterized by a typical skin-core structure as a result of general shear-induced crystallization. Unusually, the crystalline morphologies of the parts prepared by GAIM, primarily due to the penetration of secondary high-compressed gas that was exerted on the polymer melt during gas injection, featured a richer and fascinating supermolecular structure. Besides, the oriented lamellar structure, general shish-kebab structure, and common spherulites existed in the skin, sub-skin, and gas channel region, respectively; a novel morphology of shish-kebab structure was seen in the sub-skin layer of the GAIM parts of HDPE. This special shish-kebab structure (recognized as 'bending shish-kebab') was neither parallel nor perpendicular to the flow direction but at an angle. Furthermore, there was a clear interface between the bending and the normal shish-kebab structures, which may be very significant for our understanding of the melt flow or polymer rheology under the coupling effect of multi-fluid flow and complex temperature profiles in the GAIM process. Based on experimental observations, a schematic illustration was proposed to interpret the formation mechanism of the bending shish-kebab structure during GAIM process. [ABSTRACT FROM AUTHOR]