Natural fibers have the potential to replace glass fibers in fiber-reinforced composite applications. However, the natural fibers’ intrinsic properties cause these issues: 1) the mechanical property variation; 2) moisture uptake by natural fibers and their composites; 3) lack of sound, cost-effective, environmentriendly fiber-matrix compounding processes; 4) incompatibility between natural fibers and polymer matrices; and 5) low heat-resistance of natural fibers and their composites. This dissertation systematically studied the use of kenaf bast fiber bundles, obtained via a mechanical retting method, as a light-weight reinforcement material for fiber-reinforced thermoset polymer composites for automotive applications. Kenaf bast fiber bundle tensile properties were tested, and the effects of locations in the kenaf plant, loading rates, retting methods, and high temperature treatments and their durations on kenaf bast fiber bundle tensile properties were evaluated. A process has been developed for fabricating high fiber loading kenaf bast fiber bundle-reinforced unsaturated polyester composites. The generated composites possessed high elastic moduli and their tensile strengths were close to specification requirements for glass fiber-reinforced sheet molding compounds. Effects of fiber loadings and lengths on resultant composite’s tensile properties were evaluated. Fiber loadings were very important for composite tensile modulus. Both fiber loadings and fiber lengths were important for composite tensile strengths. The distributions of composite tensile, flexural and impact strengths were analyzed. The 2-parameter Weibull model was found to be the most appropriate for describing the composite strength distributions and provided the most conservative design values. Kenaf-reinforced unsaturated polyester composites were also proved to be more cost-effective than glass fiber-reinforced SMCs at high fiber loadings. Kenaf bast fiber bundle-reinforced composite’s water absorption properties were tested. Surface-coating and edge-sealing significantly reduced composite water resistance properties. Encapsulation was a practical method to improve composite water resistance properties. The molding pressure and styrene concentrations on composite and matrix properties were evaluated. Laser and plasma treatment improved fiber-to-matrix adhesion.

Cellulosic fibers sized from the macro-scale to the nano-scale were prepared hierarchically from kenaf bast fibers using chemicals. The process began with a hermetical alkaline retting followed by a bleaching treatment. The bleached fibers were hydrolyzed using inorganic acid, from which microfibers and cellulose nanowhiskers (CNWs) were fabricated. Inorganic nanoparticle impregnation (INI) was used to treat the retted fibers for the improvement of the interfacial compatibility between the fiber and polypropylene (PP) matrix. The retted fibers and INI-treated fibers were used as reinforcement for the PP polymer composites. Film casting process was used to make CNW/PVA composites. The hermetical retting process used in this study produced fibers with high cellulose contents (81-92%) by removing the lignin and hemicelluloses. Higher retting temperature resulted in higher fiber surface hardness and elastic moduli. The tensile strengths and tensile moduli of the fibers decreased as the temperature increased. The SEM images showed the micropores in the cell wall structure for the fibers retted at over 130°C, providing the possibility to anchor nanoparticles into the cell wall. Surface morphology of the INI-treated fibers was examined with SEM, and showed that the CaCO3 nanoparticle crystals grew onto the fiber surface. Energy-dispersive X-ray spectroscopy (EDS) was used to verify the CaCO3 particle deposits on the fiber surface. As the size scale of the fibers decreased, the fiber crystallinity increased from 49.9% (retted fibers) to 83.9% (CNWs). About 23% á-cellulose in the raw kenaf bast fibers had been converted into CNWs. The retted fibers without INI treatment had poor compatibility with the polypropylene matrix. The INI treatment improved the compatibility between the fibers and the PP matrix, resulting in an improvement in kenaf fiber/PP composite tensile moduli and tensile strengths. The CNWs prepared from kenaf bast fiber gave excellent reinforcement for PVA composites. A nine percent increase of CNWs in the CNW/PVA composites yielded significant improvements in tensile strength and modulus of about 46% and 152%, respectively, compared with pure PVA.

The electromagnetic shielding effectiveness of kenaf bast fiber based composites with different iron oxide impregnation levels was investigated. The kenaf fibers were retted to remove the lignin and extractives from the pores in fibers, and then magnetized. Using the unsaturated polyester and the magnetized fibers, kenaf fiber based composites were manufactured by compression molding process. The transmission energies of the composites were characterized when the composite samples were exposed under the irradiation of electromagnetic (EM) wave with a changing frequency from 9 GHz to 11 GHz. Using the scanning electron microscope (SEM), the iron oxide nanoparticles were observed on the surfaces and inside the micropore structures of single fibers. The SEM images revealed that the composite’s EM shielding effectiveness was increased due to the adhesion of the iron oxide crystals to the kenaf fiber surfaces. As the Fe content increased from 0% to 6.8%, 15.9% and 18.0%, the total surface free energy of kenaf fibers with magnetizing treat increased from 44.77 mJ/m2 to 46.07 mJ/m2, 48.78 mJ/m2 and 53.02 mJ/m2, respectively, while the modulus of elasticity (MOE) reduced from 2,875 MPa to 2,729 MPa, 2,487 MPa and 2,007 MPa, respectively. Meanwhile, the shielding effectiveness was increased from 30-50% to 60-70%, 65-75% and 70-80%, respectively.