Evaluation of the Effects of Biochar Pyrolysis Temperature and Loading on the Polyester Biocomposite Properties

Polyester resin biocomposites containing biochar have attracted attention for improving mechanical strength and thermal stability while promoting sustainability. The pyrolysis temperature of biochar and its proportion in the polymer matrix are key factors affecting biocomposite performance. This study examined how biochar pyrolysis temperatures (400, 600, 800 °C) and incorporation levels (10, 20, 30 wt.%) influence the physical, chemical, mechanical, flammability, and morphological properties of polyester-based biocomposites. The samples were analyzed for density, water absorption, FTIR, XRD, flexural and tensile strength, ignition time, structural degradation, volumetric loss, and SEM microstructure. Biocomposites with 30 wt.% biochar produced at 800 °C showed the best mechanical properties, with a flexural strength of 95.3 MPa and an elastic modulus of 4417.4 MPa, representing increases of 14.5% and 45.7%, respectively, over the control. FTIR and XRD results revealed decreased aliphatic groups and increased aromaticity at higher pyrolysis temperatures, improving interactions between the matrix and biochar. These biocomposites also demonstrated enhanced thermal stability, with an ignition time of approximately 963 s, delayed structural degradation, and reduced volumetric loss (~19.3%). Overall, pyrolysis temperature and biochar content significantly influence the structural, mechanical, and thermal properties of polyester biocomposites, showing that biochar serves as a sustainable, performance-enhancing component in thermoset polymer matrices.