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Battery failed in the middle of saving a file to a 64GB SD card in my Android phone. Now card is not recognized by phone and is telling me that it needs formatting. When inserted into PC, everything sort of locks up for about half an hour before windows even recognises that a card has been installed, then it wants me to format it.

I cancelled the format request and started photorec, which took 2 days to finish and found nothing.

I had assumed that power failure would have just messed up the file that was saving and then maybe the directory table MBR or similar, but maybe something more serious has happened, what do you suggest?

There is probably an electronic problem, you should contact a data recovery company.