Effects of coalescence and breakup on the steady state morphology of an immiscible polymer blend in shear flow

The steady-state morphology of an immiscible polymer blend in shear flow has been investigated by optical microscopy techniques. The blend is composed by poly-isobutylene (PIB) and poly-dimethylsiloxane (PDMS) of comparable viscosity. Experiments were performed by means of a home-made transparent parallel plate device. The two plates can be independently counter-rotated, so that sheared droplets of the dispersed phase can be kept fixed with respect to the microscope point of view, and observed for long times. The distribution of drops and their average size were measured directly during flow at different shear rates and for different blend compositions. It was found that the average drop size in steady-state conditions is a decreasing function of the applied shear rate, and does not depend on blend composition for volume fractions up to 10%. Experiments have proved that, in the shear rate range which could be investigated, the stationary morphology is controlled only by coalescence phenomena, droplet breakup playing no role in determining the size of the dispersed phase. More generally, it has been shown that the steady-state morphology is a function not only of the physical parameters of the blend and of the shear rate, but also of the initial conditions applied to the blend. The steady-state results reported in this paper constitute the first direct experimental confirmation of theoretical models which describe the mechanisms of shear-induced drop coalescence.