Effects of long-chain branching, short-chain branching, and polydispersity on pressure sensitive rheology of polymer melts

Abstract The rheological behavior of polymer melts under high pressure is a critical factor in many industrial processes like injection molding and extrusion, yet it is often inadequately characterized. At operating pressures that can exceed 100 MPa, viscosity can increase by orders of magnitude, making atmospheric-pressure data insufficient for accurate process simulation. This pressure-induced viscosity increase is highly dependent on molecular architectures of the materials. This study aims to deconstruct the influence of specific structural features such as short-chain branching (SCB), long-chain branching (LCB), and polydispersity on the pressure sensitivity of the viscosity of polyethylene. Utilizing a high-pressure sliding plate rheometer (HPSPR) to ensure accurate measurements under uniform shear and pressure, we characterized four distinct polyethylene melts. All samples, regardless of their structure, exhibited piezorheologically simple behavior, allowing the application of time–pressure superposition over the entire shear rate range. A key finding is that the long-chain branched sample, known from the literature to be thermorheologically complex, was found to be piezorheologically simple. This dichotomy is explained by the different physical mechanisms of temperature and pressure. The pressure sensitivity of the viscosity, quantified by the pressure–viscosity coefficient, was found to be strongly dependent on molecular branching. Both SCB and LCB significantly increase the pressure sensitivity while polydispersity had a negligible effect. These results demonstrate that molecular branches are the dominant structural parameter controlling the rheological response of polyethylene to pressure, providing crucial insights for the development of more accurate predictive models for high-pressure polymer processing.