Enhancing the Corrosion Resistance of AlCoCrFeNi High-Entropy Alloy Coatings via TiO₂ Doping

This study investigated the corrosion resistance of laser-cladded AlCoCrFeNi high-entropy alloy coatings with varying TiO₂ content (0 wt.%, 0.5 wt.%, 1.0 wt.%, and 1.5 wt.%) in 3.5 wt.% NaCl solution. Optimal cladding parameters (1500 W, 40 mm/s, 11.9 g/min) were determined via orthogonal experiments. TiO₂ promoted Ti-rich BCC2-phase precipitation, increased corrosion potential (from -1.4185 V to -0.6841 V), decreased corrosion current density (from 2.33 × 10^-4 to 2.28 × 10^-6 A/cm²), and enhanced charge-transfer resistance. XPS analysis demonstrated that TiO₂ promoted the enrichment of FeO, Cr₂O₃, and TiO₂ components in the passive film while reducing the Al₂O₃ fraction, leading to the formation of a dense and stable composite passive film that effectively inhibited chloride ion attack. In summary, an appropriate amount of TiO₂ doping significantly enhances the corrosion resistance of laser-cladded AlCoCrFeNi HEA coatings, with the 1.5 wt.% addition being the best-performing among the investigated compositions.