The phase separation of high-density polyethylene (HDPE)-polypropylene (PP) blends was studied using atomic force microscopy in tapping mode to obtain height and phase images. The results are compared with those from scanning electron microscopy imaging and are connected to the thermomechanical properties of the blends, characterised through differential scanning calorimetry, dynamic mechanical analysis (DMA), and tensile testing. Pure PP, as well as 10:90 and 20:80 weight ratio HDPE-PP blends, showed a homogeneous morphology, but the 25:75 HDPE-PP blends exhibited a sub-micrometre droplet-matrix structure, and the 50:50 HDPE-PP blends displayed a more complex co-continuous nano/microphase-separated structure. These complex phase separation morphologies correlate with the increased loss modulus (viscous properties) of the corresponding blends as measured by DMA, demonstrating the potential for the creation of strong and simultaneously tough, energy-absorbing materials for numerous applications.
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