Micro-deformation mechanisms in thermoformed alumina trihydrate reinforced poly(methyl methacrylate)

Micro-deformation mechanisms involved in thermoforming of alumina trihydrate (ATH) reinforced poly(methyl methacrylate) (PMMA) was investigated in a new experimental method replicating industrial heavy-gage thermoforming procedure. Uniaxial tension tests under non-steady thermal conditions were carried out at different forming rates and forming temperatures. Stress-strain curves and load-displacement histories of thermoformed samples were studied in terms of specimen temperature at different forming conditions. Neat PMMA samples were stretched to 50% strain under identical thermoforming conditions as PMMA/ATH for comparison purposes. Stress whitening in thermoformed PMMA/ATH samples was monitored with optical microscope and degree of stress whitening was characterized by an index obtained from optical image histograms. Micro-deformation features on the surface of PMMA and PMMA/ATH samples were examined by scanning electron microscopy (SEM). Micro-deformation in neat PMMA was in the form of homogenous drawing and did not include any type of void formation. SEM images of PMMA/ATH samples showed that particle cracking is the dominant deformation mechanism at low-forming temperatures, while at high-forming temperatures, combined particle disintegration and interfacial failure are dominant mechanisms. Stress whitening was not observed in neat PMMA which was attributed to absence of micro-voids or craze-like structures. On the other hand, PMMA/ATH samples displayed different levels of stress whitening depending on density, size and type of micro-deformation features.