Zhanfeng Qi, Hengye Zhang, Xiuli Guo, Le Geng
High-energy ball milling (HEBM) offers a pathway for the green preparation of multifunctional coatings. However, existing research lacks systematic frameworks addressing the interplay of HEBM process parameters, elemental screening criteria, and coating classification systems. This study establishes a comprehensive “elemental screening–process synergy–classification and prediction” framework for HEBM coatings. Key contributions include establishing a two-tier screening criterion based on non-radioactivity/low-toxicity and functionality for coating elements; revealing the synergistic effects of key process parameters; proposing a dual-dimensional coating classification system based on composition and function; and constructing a quantitative database encompassing 11 key performance indicators. This work provides theoretical foundations and data-driven guidance for the precise design and selection of high-performance HEBM coatings.