Influence of the thermal expansion on the surface quality of coated and non-coated natural-fiber-reinforced composites

Natural fiber reinforced plastics (NFRP) are increasingly used as a sustainable material alternative to glass or carbon fiber reinforced plastics in lightweight solutions. Visible and/or decorative coated components must meet high surface qualities and defects such as fiber print-through due to different expansion behavior of fiber and matrix are not permitted. Various studies investigate the expansion behavior of NFRP under the influence of temperature and humidity on mechanical properties. In contrast, there are no studies that relate these properties to decoratively coated NFRP and the importance for surface quality. The present study aims to fill this gap using a flax fiber reinforced bio-based epoxy resin (FFRP) manufactured by resin transfer molding process (RTM). The surface roughness and the coefficient of thermal expansion (CTE) were determined as a function of the fiber mass fraction. Further, FFRP and carbon fiber reinforced plastics (CFRP) were decoratively coated and subjected to an alternating climate test. The results showed that reducing the fiber mass fraction of an FFRP to 40 % and using a glass-fiber non-woven on the surface, in combination with 50 % fiber mass fraction, were the most promising methods for reducing roughness in the uncoated state. In addition, the FFRP exhibited an increased CTE longitudinally of 11 ppmK⁻¹ and transversely of 105 ppmK⁻¹ to the fiber direction compared to the CFRP (5 and 79 ppmK⁻¹⁾, along with increased roughness of Ra 0.8 compared to 0.6. The effect of fiber print-through was shown for all variants by the stress in the alternating climate test.