Development Status of High-entropy Ceramic Coatings with Integrated Wear and Corrosion Resistance

HU Jiezhen; ZHONG Shenghao; DENG Peichang; GENG Baoyu; LI Youchi; WU Fangming

doi:10.16490/j.cnki.issn.1001-3660.2025.22.001

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Surface Technology ›› 2025, Vol. 54 ›› Issue (22) : 1-15. DOI: 10.16490/j.cnki.issn.1001-3660.2025.22.001

Research Review

Development Status of High-entropy Ceramic Coatings with Integrated Wear and Corrosion Resistance

HU Jiezhen^a,b, ZHONG Shenghao^a,b, DENG Peichang^b,c, GENG Baoyu^a,b*, LI Youchi^a,b, WU Fangming^a,b

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Abstract

The moving components in engineering equipment are highly susceptible to significantly accelerated failure under the synergistic effects of corrosion and friction, severely impairing the reliability and service life of the equipment. In recent years, high-entropy ceramics (HECs) are characterized by multi-component single-phase solid solutions and benefit greatly from the high-entropy effect, which endows them with excellent chemical stability, corrosion resistance, and high hardness. Consequently, HECs have emerged as one of the most promising material systems for developing comprehensive wear-resistant and corrosion-resistant protective coatings. The work aims to summarize the concept, classification, composition design principles, and preparation techniques of HECs.
The basic concepts of HECs coatings are elaborated. Inspired by high entropy alloys (HEAs) and two-component ceramic coatings, Rost et al. successfully developed HECs (MgCoNiCuZn)O in 2015, confirming that configurational entropy could promote reversible transformation from multiphase to solid solution, which opened up a new direction for research on high-entropy ceramics. Unlike HEAs where metal bonds dominate, HECs form a unique solid solution structure through the synergistic action of multiple chemical bonds such as ionic and covalent bonds. Its typical feature is that multiple main elements occupy the same Wyckoff equivalent position in equal/near equal atomic ratios, forming a multi-component inorganic system with significant configurational entropy effect.
According to the types of non-metallic elements in HECs, high entropy alloys are divided into nitride high entropy ceramics (HENCs), oxide high entropy ceramics (HEOCs), carbide high entropy ceramics (HECCs), and boride noble ceramics (HEBCs). HENCs form dense crystal structures through metal-nitrogen covalent-ionic bonds, and exhibit significant lattice distortion and chemical disorder, which endows them with excellent wear resistance/corrosion resistance, making them the most studied for such coatings. Although there is limited research on the performance of HEOCs, existing studies indicate that they inherit the chemical stability of oxides in extreme acidic/alkaline environments. HECCs form a dense carbide network skeleton through covalent bonds between carbon and transition metals. At the same time, the solid solution of carbon gaps causes lattice distortion, hinders dislocation movement, and can effectively improve the hardness and wear resistance of coatings. HECCs passivation film is usually not as stable as HEN. Among all four types, HEB exhibits the best high-temperature hardness retention and resistance to environmental/molten metal corrosion, making it suitable for ultra-high temperature applications.
The elemental composition has a major impact on wear resistance and corrosion resistance. Currently, the composition design relies on semi-empirical and first-principles methods. Elemental ratios affect mixing entropy, altering microstructures that govern mechanical and corrosion behaviors. The prevailing research approach optimizes comprehensive performance by tuning individual metallic/non-metallic elements. Transition metals act as stabilizers, of which similar atomic radii and electronegativities promote stable single-phase solid solutions. Main group and rare earth elements serve as modifiers, regulating density, oxidation resistance, and amorphous-forming ability. Non-metals (N, O, C, B) critically determine crystal structures and wear and corrosion resistance performance. For HENCs coatings, an appropriate elevation in nitrogen content enhances corrosion and wear resistance, whereas nitrogen excess induces microstructural heterogeneity through phase segregation, consequently degrading performance. In HECCs coatings, incremental carbon content elevates hardness and wear resistance but concurrently diminishes corrosion resistance. Regarding HEOs coatings, although oxygen enrichment improves wear resistance, corrosion resistance first increases and then gradually decreases. In HEB system, boron promotes the formation of eutectic structure and increases hardness, but reduces corrosion resistance.
At present, these studies indicate that it is difficult to synergistically improve wear resistance and corrosion resistance, and the weak bonding strength between the coating/substrate interface has become the two key challenges faced by HECs coatings. Future research on corrosion-resistant and wear-resistant HECs coatings will exhibit multi-dimensional development trends. In terms of composition design, intelligent methods such as high-throughput computation and machine learning will gradually replace traditional trial-and-error approaches, enabling the precise design of coating materials. Regarding coating structure optimization, multi-layer or gradient designs will become effective pathways to enhance interfacial bonding strength and comprehensive performance. Concurrently, continuous innovation in novel preparation processes will further improve coating quality and properties. Particularly noteworthy is that establishing life prediction models under multi-physics field coupling conditions will become a key research direction. This will propel high-entropy ceramic coatings to make a substantial transition from fundamental research to engineering applications. As an important development direction in materials science, high-entropy ceramic coatings demonstrate immense potential in enhancing the service performance of materials and expanding novel application scenarios.

Key words

high-entropy ceramic coating / corrosion and wear resistance / component design / coating preparation process

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HU Jiezhen, ZHONG Shenghao, DENG Peichang, GENG Baoyu, LI Youchi, WU Fangming. Development Status of High-entropy Ceramic Coatings with Integrated Wear and Corrosion Resistance[J]. Surface Technology. 2025, 54(22): 1-15 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.22.001

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Funding

Natural Science Foundation of Guangdong Province (2021A1515012129); The Innovation Team Project for Ordinary Universities in Guangdong Province (2024KCXTD041); Science & Technology Development Fundation of Zhanjiang (2022A01029)