Injection and injection compression molding of ultra-high-molecular weight polyethylene powder

Ultra-high-molecular weight polyethylene (UHMWPE) powder was processed using injection molding (IM) with different cavity thicknesses and injection-compression molding (ICM). The processing parameters of feeding the powders were optimized to ensure proper dosage and avoid jeopardizing the UHMWPE molecular structure. Dynamic mechanical analysis (DMA) and Fourier-transform infrared spectroscopy tests confirmed that the thermal and oxidative degradations of the material were avoided but crosslinking was induced during melt processing. Tensile tests and impact tests showed that the ICM samples were superior to those of IM. Increased cavity thickness and ICM were helpful for reducing the injection pressure and improving the mechanical properties due to effective packing of the material. Short shot molding showed that the UHMWPE melt did not exhibit the typical progressive and smooth melt front advancements. Due to its highly entangled polymer chains structure, it entered the cavity as an irregular porous-like structure, as shown by short shots and micro-computed tomography scans. A delamination skin layer (around 300-μm thick and independent of cavity thickness) was formed on all IM sample surfaces while it was absent in the ICM samples, suggesting two different flow behaviors between IM and ICM during the packing phase. POLYM. ENG. SCI., 59:E170–E179, 2019.