Extension‐dominated improved dispersive mixing in single‐screw extrusion. Part 2: Comparative analysis with twin‐screw extruder

In Part 1 of this work, the possibility of improving single‐screw extruders (SSE) better dispersive mixer was explored by harnessing extensional flows provided by the hyperbolic contracting–diverging channels of extensional mixing elements (EME). Addition of the EME to the pin screw generated enhanced breakup for polymer blends and nanocomposite systems without significant penalty in flow rate. In Part 2, experiments are performed on immiscible polymer blends (low‐viscosity ratio and high‐viscosity ratio) and nanocomposites on both SSE and twin‐screw extruder (TSE) with the same rotation speed and throughput. Morphological results show tremendous improvement in dispersive mixing capability of SSE when equipped with EME that are mainly comparable to conventional TSE that is, with kneading blocks as mixing sections, although not as good as TSEs equipped with EMEs. Mechanical results also show enhanced modulus when EME is used in SSE operations.