Polyethylene samples have been annealed under high pressures in order
to transform the morphology and thereby make specimens, which on subse
quent orientation by hydrostatic extrusion, produce high-modulus mater
ials for comparatively low deformation ratios. The pre-extrusion morph
ology, as revealed by permanganic etching followed by transmission ele
ctron microscopy, is shown to be highly sensitive to the annealing con
ditions, especially in the vicinity of the orthorhombic/hexagonal phas
e boundary. The morphological changes have also been studied by gel pe
rmeation chromatography of nitrated samples and by differential scanni
ng calorimetry. The moduli of samples, extruded to a standard extrusio
n ratio of 7, reflect differences in the morphology of the starting ma
terial. It is shown that the highest modulus is not obtained by anneal
ing totally within the hexagonal phase but rather in the changeover re
gion between it and the orthorhombic phase. Although the lamellar size
can be dramatically increased by annealing within the hexagonal phase
, this development occurs at the expense of reducing the integrity of
the molecular network so that for high lamellar size the modulus falls
and the samples become increasingly incoherent.