Evolution of Functional Coatings on Metallic Substrates: Advanced Surface Solutions for Extreme Energy and Medical Applications

Functional coatings have evolved from their early role as passive barriers against corrosion and wear into engineered interfaces that actively mediate the interaction between a bulk material and its environment. This review traces the evolution of coating technologies from traditional macroscopic protective layers to nanoscale and multifunctional systems, and finally to smart and stimuli-responsive architectures. Advanced deposition and surface modification techniques are examined, including atomic layer deposition, physical vapor deposition, electrochemical and sol–gel approaches. The discussion is structured around two complementary application domains: extreme energy environments, focusing on coatings developed for advanced nuclear systems, and modern medical implants, including bioactive and antimicrobial surfaces and drug-delivery interfaces. The review highlights that, despite the differences between reactor and biomedical environments, both sectors share a common set of design principles and challenges, including interfacial adhesion, mechanical durability, the dual role of nanostructuring, and the trade-off between architectural complexity and operational reliability. Long-term stability, scalability, and standardized validation remain key barriers to deployment, while data-driven design and the deliberate integration of multiple functions emerge as the principal directions for future development.