Research Progress and Prospects of Corrosion-resistant High-entropy Alloy Coatings

WANG Haitao; YANG Pan; ZHAO Fan; ZENG Yi; SHAO Feng; XIANG Chao; LAI Jianping; YU Jiaxin

doi:10.16490/j.cnki.issn.1001-3660.2026.10.002

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Surface Technology ›› 2026, Vol. 55 ›› Issue (10) : 12-34. DOI: 10.16490/j.cnki.issn.1001-3660.2026.10.002

Corrosion and Protection

Research Progress and Prospects of Corrosion-resistant High-entropy Alloy Coatings

WANG Haitao, YANG Pan, ZHAO Fan^*, ZENG Yi, SHAO Feng, XIANG Chao, LAI Jianping, YU Jiaxin^*

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Abstract

The safe and reliable operation of marine equipment holds significant importance for economic development, technological innovation, and national security. However, the unique corrosive conditions in the marine environment impose stringent requirements on the corrosion-resistant coatings used for marine equipment. Unlike corrosion protection in the atmosphere, corrosion protection in marine environments is affected by multiple mechanisms, including electrochemical corrosion dominated by Cl^-, microbiologically influenced corrosion in deep-sea environments, and cavitation erosion induced by hydrodynamic effects. Cl^- in seawater readily penetrates coating defects, leading to localized pitting corrosion, which reduces coating adhesion and ultimately causes delamination. Microbiologically influenced corrosion, facilitated by biofilms, continuously generates corrosive metabolites (e.g., H₂S) that accelerate coating degradation. Cavitation erosion arises from micro-jet impacts due to bubble collapse, resulting in mechanical fatigue and spalling of the coating. These corrosive conditions make metallic materials highly susceptible to corrosion-induced failure, thereby shortening the service life of marine equipment and increasing maintenance costs. Surface coating technology has emerged as a highly efficient and cost-effective approach for corrosion protection of marine equipment, enabling the isolation of corrosive media through the application of a protective layer, thereby extending the service life. Among various coating systems, high-entropy alloy (HEA) coatings are designed at varying atomic ratios of multiple main elements, which facilitates the formation of simple solid solution structures (e.g., BCC, FCC) or a uniform amorphous phase. These microstructures are dense in nature, effectively reducing the risk of galvanic corrosion. Moreover, under the influence of corrosive media, they can form a dense passive film on the surface, thereby retarding the corrosion process and demonstrating excellent corrosion resistance.
The corrosion resistance of the HEA coating is governed by the type and concentration of corrosion-resistant elements. In particular, elements such as Cr, Al, and Mo contribute to the formation of a solid solution structure and a dense passivation film, thereby effectively enhancing the coating's resistance to corrosive media. However, excessive addition of these elements can lead to elemental segregation, which induces micro-pitting corrosion and degrades the corrosion resistance of the coatings. Furthermore, the preparation methods and processing parameters of the HEA coating strongly influence its corrosion resistance. For instance, during laser deposition, the laser power and the traversing speed of the spray gun significantly influence the porosity of the coating and the precipitation of detrimental phases, thereby affecting its mechanical properties and corrosion resistance. In addition, marine equipment exhibits diverse corrosion behaviors and mechanisms in complex service environments, including electrochemical corrosion, microbial corrosion, and cavitation erosion. The primary objective of current research on corrosion-resistant HEA coatings is to optimize coating composition and process parameters to achieve superior corrosion resistance in complex service environments.
This work reviews recent progress in corrosion-resistant HEA coatings, including classification and compositional characteristics, preparation methods and performance features, and corrosion behaviors and mechanisms in complex marine environments. Key challenges in the practical engineering application of HEA coatings are identified, including coating composition design, process optimization, and in-service performance enhancement. Based on the characteristics of marine environments, a clear optimization pathway that integrates multi-scale simulation, process-structure optimization, and in situ testing and characterization is proposed to enhance coating protection. Finally, the future development prospects of corrosion-resistant HEA coatings are discussed to provide a theoretical foundation and technical guidance for designing and engineering next-generation high-performance corrosion-resistant coatings.

Key words

high entropy alloy coatings / corrosion protection / coating preparation process / marine environment / corrosion mechanism / marine corrosive environment

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WANG Haitao, YANG Pan, ZHAO Fan, ZENG Yi, SHAO Feng, XIANG Chao, LAI Jianping, YU Jiaxin. Research Progress and Prospects of Corrosion-resistant High-entropy Alloy Coatings[J]. Surface Technology. 2026, 55(10): 12-34

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