Research Advances in the Design of Refractory High-entropy Alloys and Applications of Protective Coatings

LI Muyang; WANG Liuying; LIU Gu; WANG Bin; GE Chaoqun; ZHANG Lixuan; KANG Qingyi

doi:10.16490/j.cnki.issn.1001-3660.2026.07.015

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Surface Technology ›› 2026, Vol. 55 ›› Issue (7) : 179-200. DOI: 10.16490/j.cnki.issn.1001-3660.2026.07.015

Equipment Surface Engineering

Research Advances in the Design of Refractory High-entropy Alloys and Applications of Protective Coatings

LI Muyang, WANG Liuying^*, LIU Gu, WANG Bin, GE Chaoqun, ZHANG Lixuan, KANG Qingyi

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Abstract

Refractory high-entropy alloys (RHEAs), a novel class of materials composed of multiple high- melting-point elements, have emerged as promising candidates for extreme environment applications owing to their exceptional high-temperature strength, excellent thermal stability, and superior corrosion resistance. Typically comprising five or more principal elements in nearly equiatomic proportions, these alloys exhibit unique microstructural and mechanical characteristics that make them particularly suitable for demanding sectors such as aerospace, nuclear energy, and high-temperature chemical processing. The outstanding performance of RHEAs is primarily attributed to their inherent single-phase solid solution structures, which confers enhanced thermal stability, oxidation resistance, and wear resistance at elevated temperatures. Despite the potential, challenges still remain in optimizing the compositional design and refining the fabrication techniques for RHEAs, particularly in their use as protective coatings.
This review systematically investigates the advances in the compositional design, preparation methods, and applications of RHEA-based protective coatings. The design of RHEAs is complex, as their multicomponent nature requires balancing factors such as atomic size differences, electronegativity, and valence electron concentration to stabilize the desired phases. The strategies for designing these alloys involve semi-empirical criteria to predict phase stability, component selection based on application-specific needs, and the integration of computational tools, such as machine learning and materials informatics, which are increasingly being utilized to expedite the discovery and optimization of new alloy compositions. While current theoretical models have provided valuable insights into RHEA phase formation, further refinement is needed to develop a more comprehensive understanding of the underlying principles guiding their design. In terms of application, RHEA coatings have garnered considerable attention for their potential to enhance the performance of materials exposed to harsh environments. The use of RHEA coatings offers significant advantages in improving the high-temperature oxidation resistance, wear resistance, and corrosion resistance of materials subjected to extreme conditions. This review critically evaluates several coating techniques, including laser cladding, magnetron sputtering, and thermal spraying, which have been employed for RHEA coating preparation. Laser cladding, known for its ability to produce dense and durable coatings, is particularly suitable for applications that require high wear resistance and high-temperature stability. Magnetron sputtering, on the other hand, provides excellent control over the coating thickness and uniformity, making it ideal for producing thin, high-performance coatings. However, challenges such as oxidation during thermal spraying and the development of residual stresses in laser-clad coatings continue to impede the widespread industrial application of these materials. These issues, along with difficulties in achieving compositional homogeneity during processing, hinder the scalability of RHEA-based coatings for commercial use. Moreover, the growing potential of RHEA coatings in various extreme environments are explored. In aerospace, the need for advanced high-temperature materials is critical, and RHEAs offer a viable alternative to traditional nickel-based superalloys. The ability of RHEAs to maintain their mechanical integrity at elevated temperatures and resist oxidation makes them ideal for use in turbine engines and other high-stress aerospace components. In the nuclear energy sector, RHEAs demonstrate exceptional resistance to radiation-induced damage, which is essential for materials used in reactor components. Additionally, the excellent corrosion resistance of RHEAs positions them as ideal candidates for marine applications, particularly in the deep-sea exploration and offshore drilling industries, where equipment is subject to severe environmental stressors.
Looking toward the future, several key directions for advancing RHEA research are identified. One critical area is the integration of material design with process optimization, which includes enhancing fabrication techniques to control the microstructure and phase evolution of RHEA coatings. The continued development of high-throughput experimental methodologies, coupled with computational modeling, will be pivotal in overcoming current limitations and facilitating the scalable production of RHEA-based coatings. Furthermore, future work should focus on addressing the challenges associated with the long-term performance of RHEA coatings in complex operational environments, ensuring their reliability and durability in real-world applications.

Key words

refractory high-entropy alloys / compositional design / protective coatings / preparation process / application fields

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LI Muyang, WANG Liuying, LIU Gu, WANG Bin, GE Chaoqun, ZHANG Lixuan, KANG Qingyi. Research Advances in the Design of Refractory High-entropy Alloys and Applications of Protective Coatings[J]. Surface Technology. 2026, 55(7): 179-200

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Funding

Special Support Program for High-level Talents of Shaanxi Province (2020-44, 2025-5); Science Basic Research Program of Shaanxi Province (2025JC-YBQN-665)