Electrochemical and Mechanical Performance of Magnetron-Sputtered AlCrFeVTi High-Entropy Alloy Coatings for Lead-Cooled Fast Reactors

High-entropy amorphous materials are attracting increasing attention due to their excellent corrosion resistance and radiation tolerance in nuclear environments. In this study, novel Al2Cr16Fe50V20Ti12 high-entropy alloy (HEA) coatings with thicknesses of 900 nm and 1400 nm were synthesized via magnetron sputtering and systematically evaluated for their structural, electrochemical, and mechanical performance. X-ray diffraction confirmed the amorphous nature of the coatings, while scanning electron microscopy revealed a denser, defect-free, and more uniform morphology in the thicker coating. Electrochemical testing in a 3.5 wt.% NaCl solution demonstrated a tenfold reduction in corrosion current density and nearly a twofold increase in charge transfer resistance for the 1400 nm coating, attributed to its improved passive film stability. Finite element modeling validated the experimental load–displacement behavior and revealed well-confined and uniformly distributed stress and strain fields within the coating. These findings establish the 1400 nm Al2Cr16Fe50V20Ti12 coating as a promising candidate for protective applications in chloride-rich and radiation-intense nuclear systems.