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When aluminum is applied to paper by physical vapor deposition, substrate roughness contributes to the defect density and hygroexpansion can cause defects that impair the aluminum coating. Both effects can manifest as an increase in electrical resistance. We quantified the effect of substrate paper hygroexpansion (0–95% relative humidity) and paper surface roughness on the effective resistivity (ρEFF) of aluminum coatings. To create different degrees of roughness, five different papers weredoi:10.3390/coatings9050295 fatcat:vi3vzlqmyfa3hibxdbqdv6cck4