Predictive Modeling of Thermo-Mechanical Performance of Bio-reinforced Intumescent Epoxy Coatings for Industrial Sustainability

This study addresses the critical challenge of enhancing the thermo-mechanical performance of epoxy coatings for industrial applications by integrating agro-waste-derived bio-fillers. Employing Box Behnken Design and multi-objective optimization, bio-reinforced composites were fabricated using a 2:1 epoxy-hardener ratio Prepared samples were subjected to mechanical and thermogravimetric analysis. The composites exhibited an average mechanical properties of tensile strength TS (78.76MPa), Shore D hardness HS (60.29), and flexural strength FS (70.58MPa). Thermogravimetric analysis revealed a thermal stability threshold of 200°C, with minimal moisture absorption (~1.1% mass loss below 100°C) and 30% residual char at 500°C, indicating potential intumescent properties. Validated models yielded adjusted R² values of 0.88(TS), 0.83(HS) and 0.83(FS). Composites under optimum conditions achieved a tensile strength of 91.9 MPa, Shore D hardness of 72.4, and flexural strength of 88.4 MPa. A desirability score of 92% validated the robustness of the optimization model. Bio-reinforced coatings demonstrated comparable durability to petroleum-based alternatives while reducing synthetic additives. The findings provide a scalable framework for developing high-performance, thermally stable coatings, and advancing sustainability objectives without compromising mechanical integrity.