Metal Matrix Composite Coatings with Polymer Fillers: Fabrication Technologies, Properties, and Applications

Metal matrix composite coatings with polymer fillers are a rapidly developing class of multifunctional materials that combine the mechanical strength, electrical conductivity, and corrosion resistance of metals with the low coefficient of friction, chemical inertness, and functional versatility of polymers. This review provides a systematic analysis of metal matrix polymer composite (MMPC) coatings, covering their classification according to the metallic matrix material (Ni, Cu, Co, Al, Ti, and Zn), the type of polymer filler (fluoropolymers, thermosetting resins, biopolymers, and electrically conductive polymers), and filler morphology (particles, fibers, and microcapsules). The main fabrication technologies are considered in detail, including electrodeposition, electroless deposition, thermal spraying, and cold spray, as well as hybrid and additive methods, with a comparative analysis of their advantages, limitations, and fields of application. The effects of filler composition, particle size and concentration, and the nature of the metal–polymer interface on the structure and functional properties of the coatings are discussed, including tribological characteristics, corrosion resistance, mechanical properties, and specific functionalities such as superhydrophobicity, anti-icing, biocompatibility, and self-healing. Unlike most existing reviews, which focus either on a single fabrication method, typically electrodeposition, or on a specific metal/polymer pair, this work provides a comprehensive cross-comparison of all key technologies, including hybrid approaches and additive manufacturing. The review also systematizes unresolved challenges, including weak adhesion at the metal/polymer interface, limitations in thermal resistance, difficulties in scaling up production, and the lack of standardized testing methods, while outlining promising directions such as nanostructured fillers, self-healing systems, and environmentally friendly manufacturing technologies. This review will be useful for materials scientists, process engineers, and surface engineering specialists working in mechanical engineering, aerospace, the oil and gas sector, medical device manufacturing, and electronics, as well as for researchers developing next-generation functional coatings. The work can serve as a guide for selecting optimal matrix/filler combinations and deposition methods for specific service conditions and as a starting point for designing MMPCs with a predefined combination of multifunctional properties.