Interfacial enhancement by shish–calabash crystal structure in polypropylene/inorganic whisker composites

The polymer matrix structure and the interface are strongly influenced by filler in semi-crystalline polymer composites because the fillers have the potential to nucleate the polymer crystallization. The structure of the nucleated crystalline polymer on filler is of particular interest and is a key to the interfacial enhancement. In this work, whiskers, with a large length/diameter ratio and with a diameter (0.2–2 μm) much larger than that of carbon nanotubes but much smaller than that of common fibers, were used to nucleate crystal morphology in polypropylene (PP)/whisker composites. The crystal morphology, interfacial adhesion and tensile properties of the composites were carefully investigated. A kind of peculiar shish–calabash crystallization morphology, with whisker serves as shish and PP spherulites serves as calabash, was observed for the first time in the thin film via PLM and in the injection molded bars by SEM. The formation mechanism of this shish–calabash structure was attributed to be that only a few nuclei could be induced on the whisker surface, which develop into large PP spherulites without hindrance, and finally stringed by the whisker, forming the shish–calabash structure. As a result, a significant improvement of interfacial interaction and tensile properties has been achieved.