Evaluating mechanical properties of noncompatibilized polycarbonate/liquid crystalline polymer blends processed with layer multiplying elements

Abstract This study examines the mechanical properties and morphological characteristics of polycarbonate (PC) and liquid crystalline polymer (LCP) blends (0%, 25%, 50%, 75%, and 100% by weight) processed using layer multiplying elements (LMEs). LMEs were employed to improve dispersion without compatibilizers by inducing layering and orientation effects. The results indicate that increasing LCP concentration enhances the modulus and tensile strength due to the reinforcement of LCP fibrils, but at the cost of reduced ductility. The modulus increased from 1114 MPa (0% LCP) to 2333 MPa (100% LCP), while tensile strength reached a maximum of 102.7 MPa for neat LCP. However, LMEs did not consistently enhance mechanical properties, as simulations revealed nonuniform layering of PC and LCP. Mechanical testing showed that while LMEs aid dispersion, they also increase void formation and phase irregularities, reducing the modulus by up to 276 MPa at high LCP concentrations. Microscopy confirmed fibrillar structures at higher LCP content, improving tensile strength, but mechanical performance was dependent on LME‐induced morphology and voids. Fracture patterns varied, with cohesive failures in high‐LCP blends and brittle fractures in lower concentrations. These findings highlight the influence of LMEs on phase morphology and mechanical behavior in immiscible polymer blends. Highlights Increased concentration of LCP improves mechanical properties. Investigated LME design does not create uniform layers. More LMEs yield higher pressure during extrusion. LMEs do not improve mechanical properties in PC/LCP blends. Mechanical properties of PC/LCP blends limited by interfacial strength.