Special Issue on Design, Development, and Characterization of Advanced Materials for Modern Industry

Given the increasingly stringent requirements regarding the performance, durability, safety, and sustainability of industrial processes, the modernization of materials and manufacturing technologies has become an essential necessity for the development of contemporary industry.

This Special Issue, titled “Design, Development, and Characterization of Advanced Materials for Modern Industry”, brings together contributions reflecting the deeply interdisciplinary nature of contemporary research in advanced materials, ranging from the design and durability assessment of engineering materials to the development of functional solutions for biomedical, agricultural, and structural applications. The included papers address both fundamental degradation and failure mechanisms—such as creep, corrosion, thermal shock, and degradation in biological environments—and modern performance-enhancement strategies involving protective coatings, high-entropy alloy doping, additive manufacturing, composite materials, and bioactive systems. Furthermore, the use of advanced characterization methods—spanning microscopy and nuclear magnetic resonance to mechanical and electrochemical testing—highlights the importance of correlating structure, processing, properties, and in-service performance. Through the diversity of applications investigated—from polymer pipelines and agricultural machinery components to orthopedic implants, biomaterials, and sustainable mortars—this thematic issue offers a comprehensive overview of current research trends and the pivotal role of advanced materials in developing more sustainable, safe, and efficient technologies for modern industry.

The ongoing modernization of industrial and biomedical applications necessitates the development of materials capable of combining high mechanical performance, durability, corrosion resistance, functionality, and sustainability [1]. In this context, understanding the relationships between processing, microstructure, properties, and in-service behavior has become a central objective of research in the field of advanced materials. Studies previously published in Applied Sciences [2,3] have highlighted the importance of surface engineering and material modification strategies for enhancing wear and corrosion resistance, demonstrating that tailoring composition and processing technologies can significantly contribute to extending the service life of engineering components [2,3]. These developments underscore the need for continued research into advanced materials and the development of increasingly sophisticated characterization methods capable of meeting the ever-changing technological demands of modern industry.

Kicking off the series of contributions dedicated to the long-term behavior of advanced materials, Katouzian and their collaborators present a comprehensive analysis of the primary methods used to study creep in fiber-reinforced composite materials. The paper highlights the importance of understanding and modeling this phenomenon for assessing the performance and service life of composite structures, bringing together analytical and numerical methods—including finite element-based approaches—and recent findings from the literature. By critically comparing various computational and characterization strategies, the study provides a useful framework for selecting the appropriate method based on the specific engineering application; this contributes to optimizing the design process, reducing costs, and more rigorously estimating in-service behavior. Furthermore, the authors identify future research directions, emphasizing the need to develop increasingly accurate models to describe the viscoelastic and creep responses of modern composite materials.

Continuing research into the creep behavior and durability assessment of engineering materials, Yu Tang and his colleagues investigate the estimation of ductile creep failure life for polyethylene pipes—essential components of modern water and gas transport infrastructure. The authors propose a method based on correlating creep tests with a critical strain criterion—applied to commercial PE80- and PE100-grade pipes—to characterize non-linear viscoelastic evolution and predict the time to failure. By employing a time-dependent hardening model and validating the results against data from long-term hydrostatic tests, the study demonstrates good agreement between estimated and experimental values. The proposed method thus offers an efficient alternative to conventional long-term testing and can contribute to optimizing material selection, safety assessment, and the design of polyethylene piping systems.

Expanding the discussion from material behavior over time to protection strategies for surfaces exposed to harsh operating conditions, Munteanu and his colleagues present a comprehensive analysis regarding the use of thermally applied coatings to enhance the durability of working parts in agricultural soil-tillage machinery. The authors specifically examine thermal spray technologies and their influence on the microstructure, hardness, and resistance to friction, abrasive wear, and corrosion of agricultural components, such as plow elements. The study highlights that the performance of these coatings is closely linked to material and deposition process characteristics as well as actual operating conditions, including soil type and pH. By demonstrating the improvements achieved in mechanical behavior and component durability, the paper advocates for the use of thermal coatings as an efficient and sustainable solution for reducing wear, extending equipment service life, and lowering maintenance costs in modern agriculture.

Munteanu and his colleagues are investigating the corrosion and thermal shock behavior of coatings produced via atmospheric plasma spraying (APS) on agricultural harrow disks—components subjected to severe wear and corrosion stresses during operation. The study analyzes three types of coatings—two metallic and one ceramic, based on W₂C/WC–12Co, Cr₂O₃–4SiO₂–3TiO, and Co–Cr–Ni–W–C—evaluating their performance through electrochemical tests and electron microscopy examinations. Among the systems investigated, the Cr₂O₃–4SiO₂–3TiO-based ceramic coating demonstrated the best protective efficiency, significantly increasing charge transfer resistance and reducing corrosion current density by nearly two orders of magnitude compared to the unprotected substrate. The results highlight the potential of APS-deposited ceramic coatings to extend the service life of soil-engaging agricultural components, reduce material loss, and lower maintenance requirements.

In another article, Moldoveanu et al. analyze the use of nuclear magnetic resonance as a non-destructive method for characterizing mortars containing waste rubber from tires, developed as part of a move toward more sustainable solutions for the construction industry. The study examines the influence of rubber granules on hydration kinetics, microstructural evolution, and pore distribution in formulations that also include casein, natural hydraulic lime, and latex. Analysis of T2 relaxation time distributions enabled the differentiation of water states and their correlation with pore sizes, thereby highlighting changes in the mortar’s internal structure. Among the compositions investigated, the formulation containing 3.5% natural hydraulic lime and 5% rubber granules exhibited the most favorable microstructural characteristics. The results confirm the utility of NMR for monitoring the evolution of cement-based materials and support the valorization of tire waste in the development of eco-innovative mortars.

Continuing the effort to enhance material resistance under severe operating conditions, Rico-Cano and colleagues investigate a bulk modification strategy for B₄C-based ceramics via doping with the high-entropy alloy CoCrFeNiMo. While previous studies in this thematic issue highlighted the role of protective coatings and microstructural characterization in improving durability, this paper explores how adjusting the material composition can simultaneously optimize mechanical and electrochemical properties. Compositions containing 0.5%, 1%, 2%, and 3% by volume of the high-entropy alloy—produced via spark plasma sintering—were analyzed using scanning electron microscopy, Vickers microhardness testing, and electrochemical methods following exposure to artificial seawater. The results indicate that increasing the CoCrFeNiMo content promotes the formation of a denser microstructure and reduces the grain size, correlating with improved mechanical strength and corrosion resistance. The study thus underscores the potential of high-entropy alloys in the design of advanced ceramics intended for demanding applications and aggressive environments.

Moving beyond the optimization of material composition and properties for harsh operating conditions, attention is shifting toward biomedical applications, where material design must align not only with mechanical loads but also with the patient’s biological and anatomical requirements. In this context, McCloskey and colleagues present a narrative review of patient-specific, 3D-printed porous metal implants, focusing on their use in orthopedics. The paper synthesizes advances in materials, additive manufacturing methods, digital design workflows, and porous structure architecture, highlighting how manufacturing parameters influence stiffness, fatigue strength, surface roughness, and osseointegration. The authors discuss both the advantages of these solutions for treating complex bone defects and atypical joint spaces and the limitations—such as costs, accessibility, and the need for further clinical evidence—that still hinder their widespread adoption. Emerging trends such as novel materials, workflow optimization, 4D printing, and cost-reduction strategies are also analyzed, outlining the increasingly important role of additive manufacturing in the development of next-generation orthopedic implants.

Continuing the theme of orthopedic implants and the relationship between material design, manufacturing, and clinical performance, Adam and colleagues analyze the potential failure mechanisms associated with Birmingham-type hip resurfacing arthroplasty. The study focuses on the characteristics of the cement layer and the bone–cement and cement–prosthesis interfaces, employing radiographic assessments, stereomicroscopy, scanning electron microscopy, and histopathological examination. The results reveal an uneven cement distribution, areas of excessive thickness, insufficient lateral coverage, and microstructural defects—including cracks, air inclusions, and signs of debonding at the cement–prosthesis interface. These observations suggest that implant failure may stem from the complex interplay between the cementing technique, the morphology of the cement mantle, and the local biological response. The study thus highlights the value of microscopic methods in identifying mechanisms of interfacial degradation and in enhancing the understanding of factors influencing the durability of orthopedic implants.

In the same field of materials for orthopedic applications, Antoniac and his colleagues are investigating the degradation behavior of antibiotic-loaded biomaterials developed for the local delivery of antimicrobial agents to the infection site. The study compares resorbable calcium sulfate-based systems—loaded with gentamicin, vancomycin, or combinations thereof—against a CaSO₄ control material and a polymethyl methacrylate (PMMA) acrylic bone cement. Structural and surface characterization—conducted via FTIR spectroscopy, scanning electron microscopy (SEM) with EDS analysis, contact angle measurements, and immersion tests—reveals the influence of the antibiotics on wettability, microstructure, and degradation profiles. The calcium sulfate-based samples, particularly those loaded with gentamicin, exhibited more hydrophilic surfaces and a microstructure conducive to interaction with aqueous media—characteristics relevant to the efficacy of local antibiotic delivery systems. By correlating composition with degradation and surface properties, the study highlights the potential of these biomaterials to optimize the local treatment of infections associated with orthopedic procedures.

Concluding the section dedicated to biomaterials, Dragomir and colleagues analyze recent advances in the development of bioactive composite dressings based on hydroxyapatite and collagen for the regeneration of complex and chronic wounds. The paper highlights how the combination of collagen’s biomimetic architecture and hydroxyapatite’s bioactivity can support tissue regeneration processes while allowing for the tuning of mechanical properties, porosity, and degradation behavior. Modern fabrication methods are discussed—such as *in situ* and biomimetic mineralization, freeze drying, electrospinning, processing into hydrogels and films, and emerging 3D printing technologies. Significant emphasis is placed on antimicrobial strategies, including the use of metal ions, locally administered antibiotics, and essential oils with antimicrobial, antioxidant, and anti-inflammatory potential. Available preclinical data indicate improvements in epithelialization and collagen deposition, as well as a reduction in bacterial load; however, the authors underscore the need for formulation standardization and clinical validation. With its integrative perspective on regeneration, antimicrobial functionalization, and fabrication technologies, this article provides a fitting conclusion to the thematic issue, illustrating how advanced materials can evolve from simple structural scaffolds into multifunctional systems that play an active role in tissue repair and protection.

The papers collected in this Special Issue highlight the increasingly interdisciplinary nature of research in the field of advanced materials and demonstrate the close link between material design, processing technologies, microstructure, characterization, and in-service performance. The studies cover a wide range of industrial and biomedical applications, from polymer pipelines, protective coatings, and advanced ceramics to additively manufactured implants, degradable biomaterials, and bioactive composites. Despite the diversity of the systems investigated, a common objective emerges: the development of materials and manufacturing technologies capable of simultaneously enhancing durability, functionality, safety, and sustainability.

A key direction for future research is the development of integrated approaches that combine material design with advanced numerical modeling, experimental characterization, and the predictive assessment of long-term behavior. Multiscale and multiphysics modeling, the finite element method, and data-driven methods can contribute to a deeper understanding of the relationships between processing parameters, microstructural evolution, degradation mechanisms, and macroscopic properties. Such approaches are particularly important for materials and components subjected to complex operating conditions characterized by the simultaneous action of mechanical, thermal, chemical, and environmental stresses [4].

Surface engineering and material modification will continue to be important avenues for extending the service life of industrial components. Future research should aim not only to optimize coating composition and deposition parameters but also to investigate the long-term behavior of coated systems under combined conditions of wear, corrosion, thermal cycling, and mechanical stress. In parallel, the development of high-entropy alloys and their use in modifying conventional materials offer new possibilities for creating systems with mechanical, thermal, and electrochemical properties tailored to severe operating conditions [5].

Additive manufacturing represents another major avenue of development. Beyond its use in rapid prototyping, current research is shifting toward the direct production of functional components with geometries and properties tailored to specific applications. Future progress requires tighter control over the relationship between process parameters, microstructure, and material properties, as well as a reduction in manufacturing defects, improvements in surface quality and fatigue resistance, and the development of reliable qualification and standardization procedures [6]. Integrating additive manufacturing with topology optimization, computational design, and CAD/CAE tools can facilitate the development of lightweight, porous, or functionally graded structures that are difficult or impossible to produce using conventional technologies.

Advanced characterization methods will, in turn, play an important role in supporting these developments. Future research should increasingly combine complementary techniques—such as electron microscopy, spectroscopic methods, electrochemical analysis, non-destructive testing, and *in situ* or *operando* characterization—to monitor the structural and functional changes that occur during processing and service. Correlating these experimental methods with digital data analysis can facilitate the early identification of degradation mechanisms and improve predictions regarding component service life and reliability [7].

In the biomedical field, future research will increasingly focus on developing multifunctional, personalized materials capable of combining mechanical compatibility, controlled degradation, bioactivity, antimicrobial properties, and tissue integration. Additively manufactured porous implants, resorbable systems for local drug delivery, and bioactive composite structures represent particularly promising avenues. However, translating these solutions from the experimental stage to clinical application requires improved standardization of manufacturing and characterization processes, long-term biological evaluations, reproducibility studies, and rigorous clinical validation [8,9].

Sustainability must also be integrated as early as the design stage for materials and manufacturing technologies. Future directions should include using recycled or secondary raw materials, reducing material and energy consumption, extending component service life, developing repair and remanufacturing strategies, and assessing the life cycle of new materials and technologies. In this way, improvements in technical performance can be aligned with reduced environmental impact and long-term economic benefits.

An emerging direction with significant potential involves integrating artificial intelligence, machine learning, the digital twin concept, and high-performance computational methods into materials development. These tools can accelerate the identification of relationships between composition, processing, microstructure, and properties; support the optimization of processing parameters; and aid in predicting material behavior under actual operating conditions. Integrating experimental data with numerical models and artificial intelligence algorithms could, in the long term, lead to the development of predictive design systems for materials and processes [8].

Despite the significant progress highlighted by the contributions in this Special Issue, research into advanced materials must continue, as the demands of modern applications are constantly evolving, necessitating materials with superior mechanical performance, enhanced durability, resistance to harsh environments, improved biocompatibility, and reduced environmental impact. The development of new compositions, processing technologies, and characterization methods is essential for a deeper understanding of the relationship between structure, properties, and performance and, by extension, for translating research findings into safer, more efficient, and sustainable solutions for industry and medicine.