Rheology–Performance Framework for <scp>PA6</scp> / <scp>GO</scp> Nanocomposites via a Hybrid Processing Route

ABSTRACT Balancing melt processability with stiffness and heat resistance remains a central challenge for PA6 nanocomposites. Here, graphene oxide (GO) was synthesized by a modified Hummers method and incorporated into PA6 via a hybrid route (solution‐made masterbatch, melt dilution and injection molding) at 0.1–2.0 wt%. Melt rheology at 240°C shows higher zero‐shear viscosity and stronger shear thinning, while SAOS and Cole–Cole plots reveal the development of a GO‐induced network. Capillary rheometry over 80–11,500 s −1 indicates viscosity convergence to Pa s for all compositions, confirming preserved moldability. By tracking / before and after injection molding, we show that the second melt‐processing step relaxes, but does not destroy, the filler‐induced network and shifts the onset of rheological percolation to around 2 wt% GO. In the solid state, DMA and HDT demonstrate a increase of ≈6°C–8°C, a 21% rise in HDT (80.8°C–97.7°C) and higher rubbery modulus, whereas tensile tests reveal up to +22% yield stress and +59% ultimate strength at 2 wt% GO, at the cost of reduced ductility. Correlating unified rheological parameters with HDT and tensile data yields a concise rheology‐to‐performance map, with an optimum near 1 wt% GO. The results link injection relevant melt signatures to molded part performance, targeting electrical connector housings.