Adding silica nanofiller in silicone rubber can toughen the matrix 3 orders in terms of fracture energy, which is far larger than most other nanofiller–rubber systems. To unveil the astonishing toughening mechanism, we employ in situ synchrotron radiation X-ray nanocomputed tomography (Nano-CT) technique with high spatial resolution (64 nm) to study the structural evolution of silica nanofiller in silicone rubber matrix at different strains. The imaging results show that silica nanofiller forms three-dimensional connected network, which couples with silicone chain network to construct a double-network structure. Stress-induced phase separation between silica nanofiller and silicone polymer chain networks is observed during tensile deformation. Unexpectedly, though the spatial position and morphology of nanofiller network changes greatly at large strains, the connectivity of nanofiller network shows negligible reduction. This indicates that nanofiller network undergoes destruction and reconstruction simultaneously, during which silica nanofiller serves as reversible high functionality cross-linker. The reversible bonding between silica nanofiller and silicone rubber or between nanofiller particles can dissipate mechanical energy effectively, which may account for the 3 orders enhancement of toughness.

The effect of flow on crystallization is commonly attributed to entropic reduction, which is caused by stretch and orientation of polymer chains but overlooks the role of flow on final-state free energy. With the aid of in situ synchrotron radiation wide-angle X-ray diffraction (WAXD) and a homemade constrained uniaxial tensile testing machine, polycrystals possessing single-crystal-like orientation rather than uniaxial orientation are found during the constrained stretch of natural rubber, whereas the c-axis and a-axis align in the stretch direction (SD) and constrained direction (CD), respectively. Molecular dynamics simulation shows that aligning the a-axis of crystal nuclei in CD leads to the lowest free energy increase and favors crystal nucleation. This indicates that the nomenclature of strain-induced crystallization may not fully account for the nature of flow-induced crystallization (FIC) as strain mainly emphasizes the entropic reduction of initial melt, whereas stress rather than strain plays the dominant role in crystal deformation. The current work not only contributes to a comprehensive understanding of the mechanism of flow-induced crystallization but also demonstrates the potential application of constrained uniaxial tensile stretch for the creation of functional materials containing polycrystals that possess single-crystal-like orientation.

On the basis of research method in FTIR imaging, we made a heterogeneous thin film of isotactic polypropylene (iPP) that contains a few large spherulites (∼150 μm) which are surrounded by small spherulites (∼15 μm) for tensile testing. The evolution processes of crystalline and amorphous orientations of iPP are monitored with its characteristic peaks at 998 and 973 cm−1, respectively. By introducing the correlation images, the analysis demonstrates the relationships between the orientation evolutions of crystalline and amorphous phases in a space of 250 μm × 250 μm detecting area. During the plastic deformation, crystalline orientation is higher than amorphous orientation outside the large spherulite, while that is opposite inside the region. In addition, the evolutions of crystalline and amorphous orientations almost keep a positive correlation.

Aiming to study the mechanical enhancement by the filler network in a rubber composite, three-dimensional images are acquired with in situ full field transmission X-ray microscopy (TXM), and the network structure of carbon black (CB) aggregates in a rubber matrix are studied with and without strain. Statistical analysis shows that the frequency of similar-sized aggregates decreases with the increase of aggregate size as well as the inter-aggregate distance monotonically without strain. An oscillation of the frequency-size plot is induced by strain on top of the damping trend, which is interpreted as stretch-induced breakage and re-aggregation of CB aggregates. Calculations adopting a soft-hard network model, predict a reduction of the contribution of the CB network to the mechanical property of the rubber composite by about 60%, caused by the breakage and re-aggregation of CB aggregates compared to those without strain. The experimental results directly prove the structural origin of the Payne effect and also show that TXM is a valuable tool to study the mechanical enhancement mechanism of filled rubber composites.

The plastic deformation behavior of isotactic polypropylene (iPP) film is studied with in-situ Fourier transformation infrared microspectroscopic imaging (FTIRI). During uniaxial tensile test, spatial distributions of crystallinity and orientations are obtained in necking region (NR), transition front (TF) and non-necking region (NNR). A low valley of crystallinity exists at TF, while both NNR and NR have crystallinities at a high plateau. This provides a direct evidence of deformation-induced melting–recrystallization mechanism of plastic deformation. The non-monotonic evolution of amorphous orientation from NR, TF to NNR further supports the occurrence of deformation-induced melting–recrystallization. The decrease of amorphous orientation behind TF is attributed to recrystallization.