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.