Acoustic Emission Mechanisms During Polymer Processing and Chain Orientation: From Amorphous to Crystalline

Acoustic emission (AE) technology has emerged as a highly sensitive and non-destructive method for the real-time monitoring of defect formation and microstructural changes during the manufacturing and early service life of polymeric materials and composites. This review highlights the fundamental principles and applications of AE in detecting crystallization-induced defects, such as cavities, dislocations, and microcracks, as well as plastic deformation mechanisms, including chain orientation, cavitation, and stress release. It is shown that AE activity correlates strongly with crystallinity and processing conditions, providing critical insights into microstructure-property relationships. The possible mechanisms can be the friction between grain boundaries, the local stress release, chain movement, phase changing, and fiber/filler debonding, among others. A comprehensive understanding can help with the prediction/prevention of early defects in the crystalline polymer processing. Furthermore, integrating AE with artificial intelligence and multi-sensor data fusion offers promising pathways toward smart, adaptive manufacturing systems capable of real-time quality control and early defect diagnosis in high-performance polymer composites.