Research status and prospects of metal/ceramic composite functional protective coatings

Metal materials, as traditional structural materials, are extensively utilized but face severe challenges such as wear and corrosion. Research has demonstrated that metal/ceramic composite functional protective coatings integrate the advantages of both metallic coatings and ceramic coatings. These coatings can provide metal materials with enhanced corrosion protection, wear resistance, and erosion resistance, thus effectively prolonging their service life. This paper collects and analyzes six conventional surface technologies and one emerging technology for fabricating metal/ceramic composite functional protective coatings. First, a comprehensive summary and analysis are conducted on the fundamental principles, coating morphologies, and coating performance associated with each technology. Second, the protective mechanisms and failure behaviors of the composite coatings are examined in the context of their diverse application fields. Finally, the key technical challenges that may arise during the preparation of metal/ceramic composite functional protective coatings are systematically analyzed, along with potential future research directions.