Mechanical Performance of Protective Epoxy Coatings with Bio-Based Ingredients for Flax–Fiber Composites

Abstract

Due to its long and continuous cellulose fibers, flax offers excellent specific tensile strength and stiffness relative to other natural fibers such sisal or jute, and it is widely used as fiber reinforcement in composites with relevance in industries such as automotive, sports and maritime environments. However, the use of natural fibers poses additional challenges relative to synthetic fibers in ensuring the functional lifetime of composites; in particular, water resistance and resistance against UV conditions should be improved for outdoor use. Therefore, a protective coating that offers high resistance against environmental conditions and mechanical damage can be applied to avoid direct surface exposure of natural fibers. The linseed oil or wax coatings increase the hydrophobic surface properties and limit water ingress, but they have drawbacks such as extended curing periods via oxidative crosslinking and weak mechanical performance. In seeking alternatives for natural fiber composites, the potential of bio-based crosslinked coatings to enhance mechanical robustness, surface protection and durability was explored by screening various coating grades, including bio-based epoxy resin, diluents and crosslinkers. The epoxy coatings with a bio-based phenalkamine crosslinker offer higher hardness and scratch resistance, and the water resistance was improved in the presence of an amine crosslinker with long alkyl chains. In parallel, the mechanical abrasion resistance of the crosslinked coatings significantly increased in relation to the intrinsic mechanical properties and crosslinking density of the coatings. The processing of the epoxy coatings was further enhanced by adding a bio-based trifunctional diluent with low viscosity while providing limited shrinkage and good compatibility with the composite substrate. Moreover, the UV resistance was better for epoxy coatings with a bio-based diluent, likely via migration effects and the formation of a protective layer at the outer surface.

Keywords

• composites
• lifetime
• protection
• coating
• water resistance
• mechanical resistance