Impact of Processing Parameters on the Morphology and Performance of PE / PA6 / EVOH Blends

ABSTRACT This study employs a stepwise approach to investigate the influence of processing conditions and blend composition on the morphology and mechanical properties of immiscible polymer blends. In the first step, a binary blend of virgin polyethylene (PE) and polyamide 6 (PA6) is processed under varying temperature profiles and extrusion speeds to promote the formation of a microfibrillar morphology. In the second step, a ternary blend of PE, PA6, and ethylene vinyl alcohol copolymer (EVOH) is processed under similar conditions to evaluate the effect of added components. Finally, a ternary blend composed of postconsumer multilayer packaging waste containing PE, EVOH, and PA6 is processed under conditions optimized to promote fibrillation. All blends are characterized using optical microscopy, photo‐induced force microscopy (PiFM), and tensile testing. The relationships between morphology and processing conditions, as well as between morphology and mechanical performance, are analyzed. Results show that the recycled ternary blend derived from multilayer packaging exhibits improved mechanical properties compared to the ternary blend prepared from virgin polymers. This enhancement is attributed to the presence of residual additives and adhesive tie layers in the original films, which act as built‐in compatibilizers and enhance phase dispersion in the recycled blend.