Multilayer design of sustainable multifunctional Zr–Cu–N coatings: A route for enhanced mechanical and antibacterial performance

• Developed sustainable Zr-Cu-N coatings with superior hardness and damage tolerance. • Elastic ZrCu, hard ZrN, and hard-tough ZrN-Cu synthesized by using only three elements. • Optimized multilayer architecture enhances mechanical properties by integration of ZrCu and ZrN-Cu nanocomposite. • Effective antimicrobial performance demonstrated in high-traffic environments over 60 days. Wear-resistant protective coatings with antimicrobial activity are essential for durability and hygiene in healthcare, public spaces, food industry, consumer products, and industrial environments. This study developed sustainable multifunctional Zr-Cu-N coatings with exceptional damage tolerance, and antibacterial properties using non-reactive and reactive sputtering of only two elemental Zr and Cu targets without external heating. The coatings’ superior performance stems from a sophisticated multilayer architecture combining elastic ZrCu metallic glass, hard and stiff ZrN ceramic, and hard and tough ZrN-Cu nanocomposite coatings. Each constituent was optimized for composition and mechanical properties before integration into multilayer structures to provide high damage tolerance and antibacterial functionality. Antibacterial efficacy was tested in a high-traffic environment over 60 days, showing consistent antimicrobial performance. Fracture stress and toughness were assessed through in situ bending experiments on microcantilever beams fabricated by focused ion beam milling. Results revealed that optimizing the thicknesses of ductile and stiff sublayers significantly enhances damage tolerance while maintaining high hardness and wear resistance. The incorporation of Cu in an unbonded state within the ZrN-Cu nanocomposite facilitates sustainable and scalable production of these multifunctional coatings with antibacterial properties, making them ideal for large surface applications in high-traffic environments like hospitals, office buildings, and public transport.