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

• • Atmospheric plasma-sprayed FeCoCrNiMn HEA coatings (Cao et al., 2024) demonstrate simultaneous resistance to seawater corrosion and tribo-corrosion, with the BCC/FCC solid solution suppressing galvanic coupling that degrades conventional multi-phase coatings; this directly extends service life of marine hydraulic components where combined wear-corrosion accounts for >60% of premature failures. • • HVOF-sprayed FeCrNiCoAl coatings (Wang et al., 2024) exhibit excellent tribocorrosion resistance in artificial seawater, with the dense splat microstructure and Cr-rich passive film reducing material loss rates by an order of magnitude versus arc-sprayed baselines; this validates HVOF as a viable route for propeller shafts and pump impellers operating under continuous cavitation. • • (FeCoCrNi)75B15Si10 high-entropy amorphous alloy coatings (Song et al., 2025) prepared by plasma spraying achieve superior corrosion-wear synergy, where the amorphous phase eliminates grain boundaries and associated preferential corrosion paths; the B/Si addition lowers critical cooling rate for glass formation, enabling practical thermal spray deposition on industrial-scale substrates. • • Mo-based HEA coatings developed by HVOF (Oppong Boakye et al., 2023) for high-temperature geothermal applications maintain corrosion resistance at elevated temperatures where conventional Ni-based coatings fail; this expands the operational envelope for marine and offshore equipment exposed to hydrothermal vents or high-temperature brine systems.