Mapping surface defects in highly-filled wood fiber polymer composite extrusion from inline spectral analysis

Surface defects in highly-filled wood polymer composites (WPCs) are mapped in single-screw extrusion via inline optical spectral analysis for the first time. The effects of wood fiber content and drying on the dynamics of surface defects are spatio-temporally resolved via space–time inline optical imaging. Surface tearing appeared from the lowest shear rates investigated followed by a gradual decay in spectral intensity with increasing shear rates/slip velocities. This is accompanied by broadening of the surface tearing characteristic frequency while the average wavelength is estimated to remain constant within the experimental conditions. Increasing shear rates, drying and increasing wood fiber content showed mitigating effects on surface tearing. However, surface tearing in undried samples was still present even at the highest shear rates and high wall slip velocities. A regime where the extrudate surface is dominated by bubbles at high shear rates and low wood fiber contents in undried WPCs was identified.