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Abstract Nanostructured epoxy composite resins have broad usage in adhesives, coatings, composites, and 3D printing. With these materials, careful control of the rheological properties is critical to ensuring that the properties meet their required performance targets. However, it can be difficult to accurately measure the rheological properties. In this work, we establish a method to develop a reliable pre-shear (PS) procedure to repeatably measure the apparent yield stress of the resins, which is critical to ensure the accurate understanding of the material behavior. The resins in this study consisted of an epoxy resin with nanoclay as a shear thinning agent, ionic liquid (1-ethyl-3-methylimidazolium dicyanamide) as a latent curing agent, and poly(ethylene oxide-b-propylene oxide-b-ethylene oxide) block copolymer (BCP) as a nanostructured component. We establish a methodology to evaluate the effectiveness of a pre-shear protocol and evaluate several methods to identify a pre-shear procedure that resulted in repeatable transient creep results on a rheometer. We identified that large amplitude oscillatory shear was the most effective method for these materials, and the optimal magnitude of the shear was dependent on the composition of the epoxy resins. Through the consistent application of this approach, we were able to use transient creep testing to identify the phase boundaries in the epoxy/BCP resins when the BCP micelles undergo an order-order transition from spherical to hexagonal micelles through changes in the yield stress of the material. This work adds to the new growing body of literature demonstrating the importance of establishing rigorous pre-shear conditions to improve the accuracy of structured yield stress fluids. 

The nonlinear response of yield stress fluids remains difficult to predict and control. Here, we show that the height of the overshoot in the loss modulus G00, a key characteristic of yielding, depends only on linear viscoelastic properties. Furthermore, the position of this overshoot depends on linear viscoelastic and flow properties, demonstrating the important and enduring role of elasticity in yielding. The physics governing linear viscoelasticity is therefore not only preserved during yielding but also controls two commonly reported yielding metrics. 

Many soft materials yield under mechanical loading, but how this transition from solid-like behavior to liquid-like behavior occurs can vary significantly. Understanding the physics of yielding is of great interest for the behavior of biological, environmental, and industrial materials, including those used as inks in additive manufacturing and muds and soils. For some materials, the yielding transition is gradual, while others yield abruptly. We refer to these behaviors as being ductile and brittle. The key rheological signatures of brittle yielding include a stress overshoot in steady-shear-startup tests and a steep increase in the loss modulus during oscillatory amplitude sweeps. In this work, we show how this spectrum of yielding behaviors may be accounted for in a continuum model for yield stress materials by introducing a parameter we call the brittility factor. Physically, an increased brittility decreases the contribution of recoverable deformation to plastic deformation, which impacts the rate at which yielding occurs. The model predictions are successfully compared to results of different rheological protocols from a number of real yield stress fluids with different microstructures, indicating the general applicability of the phenomenon of brittility. Our study shows that the brittility of soft materials plays a critical role in determining the rate of the yielding transition and provides a simple tool for understanding its effects under various loading conditions. 

Linking the macroscopic flow properties and nanoscopic structure is a fundamental challenge to understanding, predicting, and designing disordered soft materials. Under small stresses, these materials are soft solids, while larger loads can lead to yielding and the acquisition of plastic strain, which adds complexity to the task. In this work, we connect the transient structure and rheological memory of a colloidal gel under cyclic shearing across a range of amplitudes via a generalized memory function using rheo-X-ray photon correlation spectroscopy (rheo-XPCS). Our rheo-XPCS data show that the nanometer scale aggregate-level structure recorrelates whenever the change in recoverable strain over some interval is zero. The macroscopic recoverable strain is therefore a measure of the nano-scale structural memory. We further show that yielding in disordered colloidal materials is strongly heterogeneous and that memories of prior deformation can exist even after the material has been subjected to flow. 

Empirical rules play a crucial role in industrial and experimental settings for efficiently determining the rheological properties of materials, thereby saving both time and resources. An example is the Cox–Merz rule, which equates the steady-shear viscosity with the magnitude of the complex viscosity obtained in oscillatory tests. This empirical rule provides access to the steady-shear viscosity that is useful for processing conditions without the instabilities associated with experiments at high shear rates. However, the Cox–Merz rule is empirical and has been shown to work in some cases and fail in others. The underlying connection between the different material functions remains phenomenological and the lack of a comprehensive understanding of the rheological physics allows for ambiguity to persist in the interpretation of material responses. In this work, we revisit the Cox–Merz rule using recovery rheology, which decomposes the strain into recoverable and unrecoverable components. When viewed through the lens of recovery rheology, it is clearly seen that the steady-shear viscosity comes from purely unrecoverable acquisition of strain, while the complex viscosity is defined in terms of contributions from both recoverable and unrecoverable components. With recovery tests in mind, we elucidate why the Cox–Merz rule works only in a limited set of conditions and present an approach that could allow for universal comparisons to be made. This work further highlights the significance of recovery rheology by showing how it is possible to extend beyond phenomenological approaches through clear rheophysical metrics obtained by decomposing the material response into recoverable and unrecoverable components. 

Understanding the yielding of complex fluids is an important rheological challenge that affects our ability to engineer and process materials for a wide variety of applications. Common theoretical understandings of yield stress fluids follow the Oldroyd–Prager formalism in which the material behavior below the yield stress is treated as solidlike, and above the yield stress as liquidlike, with an instantaneous transition between the two states. This formalism was built on a quasi-static approach to the yield stress, while most applications, ranging from material processing to end user applications, involve a transient approach to yielding over a finite timescale. Using stress-controlled oscillatory shear experiments, we show that yield stress fluids flow below their yield stresses. This is quantified through measuring the strain shift, which is the value about which the strain oscillates during a stress-controlled test and is a function of only the unrecoverable strain. Measurements of the strain shift are, therefore, measurements of flow having taken place. These experimental results are compared to the Herschel–Bulkley form of the Saramito model, which utilizes the Oldroyd–Prager formalism, and the recently published Kamani–Donley–Rogers (KDR) model, in which one constitutive equation represents the entire range of material responses. Scaling relationships are derived, which allow us to show why yield stress fluids will flow across all stresses, above and below their yield stress. Finally, derivations are presented that show strain shift can be used to determine average metrics previously attainable only through recovery rheology, and these are experimentally verified.