Development of Biochar-Based Sustainable Corrosion-Resistant Coating

Conventional protective coatings based on petroleum raw materials have certain limitations in terms of their availability, environmental pollution, and sustainability. Therefore, this research successfully investigates the potential of sheep wool-derived biochar to develop a sustainable, high-performance protective coating. Two variants of biochar, namely SW800 and SW1000, were developed by pyrolyzing sheep wool at 800 °C and at 1000 °C for 1 h, respectively. The prepared samples were characterized using FTIR, FESEM-EDX, and XRD analyses to confirm the structural and elemental differences between both biochar samples. Furthermore, biochar-based epoxy coatings were developed by varying the concentration of prepared biochar from 1% to 5%. The coating performance was evaluated for its aesthetic, mechanical, chemical resistance, and hydrophobicity. Crucially, this study demonstrated that biochar inclusion did not compromise critical mechanical and chemical properties like adhesion (5B), flexibility (7 mm), scratch hardness (3500 gms), pencil hardness (3H), acid-alkali resistance, and solvent rub test (rating 5). However, a key finding of this research is that the incorporation of biochar into an epoxy coating resulted in a significant improvement in hydrophobicity, which is measured using water contact angle. The incorporation of SW800 and SW1000 into coating formulations at varying concentrations resulted in an increase in water angle of approximately 18% and 20%, respectively. The outcomes of this project establish biochar-based coatings as a promising solution for eco-friendly and high-performance protective applications.