Water-assisted melt-intercalation process is a relatively new method for nanocomposite production. Technical challenges notwithstanding, this process is capable of bringing forth good results and promising advantages. Having used this process, we produced composites in a twin-screw extruder. The aim of this study was to find, through a designed set of experiments, the conditions that result in producing nanocomposites. In this study, the main focus of our characterization phase was on rheological behavior. We then used mechanical testing, X-ray diffraction, and atomic force microscopy for verification purposes. The results obtained from these techniques were manifold; therefore, we used response surface method to present them intelligibly. After examining different modifiers, we concluded that chain length, packing density, and cation exchange selectivity are important parameters for choosing proper modifier type. Plus, as has been reported by other groups, this process was found to be mainly diffusion-controlled rather than shear-controlled.
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