Design and Development of Microcapsules Based Sustainable Highly Resistant and Self‐Healing Anticorrosive Epoxy Coatings

ABSTRACT Bio‐based, green, and sustainable self‐healing anticorrosive coatings derived from renewable bioresources such as vegetable oils have attracted growing interest due to increasing environmental challenges and the need for cost‐effective maintenance strategies. This study introduces Perilla Oil (PO), encapsulated within poly(urea‐formaldehyde) (PUF) microcapsules via an in situ polymerization oil‐in‐water emulsion technique, as an eco‐friendly, efficient self‐healing agent. The microcapsules exhibit robust morphology, size homogeneity, and thermal stability confirmed by optical microscopy, SEM, FTIR, TGA, DSC, and particle size distribution analyses, achieving encapsulation efficiencies exceeding 60.0%. Incorporation of 7.0 wt% PO microcapsules into epoxy coatings facilitates rapid self‐healing of surface cracks within 24 h through auto‐oxidation‐induced polymerization of the released PO. Immersion tests in aggressive saline and acidic environments demonstrate significantly enhanced corrosion resistance, adhesion durability, and coating integrity compared to control samples, which exhibited accelerated corrosion and delamination. The oxidatively polymerized PO effectively acts as an oxygen and moisture barrier, illustrating a novel mechanism for in situ self‐healing protective film regeneration. These environmentally benign coatings have promising industrial potential in sectors including marine infrastructure, automotive, aerospace, and heavy machinery, where sustainable corrosion protection is paramount. Their use contributes to decarbonization efforts and aligns with global sustainability goals. Further development, including scaling production and integrating biodegradable shell materials, could broaden practical applicability and market acceptance of this innovative technology.