PentestChain: A Cost-Aware, MCP-Orchestrated Framework for Automated Penetration Testing with Free-Tier LLMs

AI-driven penetration testing has been demonstrated with premium frontier models such as GPT-4, but the per-engagement token cost makes continuous, automated testing unaffordable for the smaller organisations that need it most. This paper presents PentestChain, a ten-phase automated penetration testing framework that couples a curated, deterministic exploit map with a cost-aware AI cascade-a local Ollama model (qwen2.5-7b) first, then free-tier OpenRouter and Cerebras, with a rule-based fallback that always produces output-and exposes the full pipeline through a Model Context Protocol (MCP) server with eleven tools. We make three contributions. First, we treat US-dollar cost per engagement as a measured, first-class evaluation metric and show that a 7B-parameter local model, kept off the critical path by a deterministic backbone, sustains end-to-end operation at zero measured paid-API cost. Second, we analyse the attack surface that an MCP-exposed offensive engine introduces, grounding a four-position threat model in the 2025 MCP incident record (the CVE-2025-6514 remote-code-execution flaw in mcp-remote, the postmark-mcp supply-chain backdoor, and the tool-poisoning-rug-pull-line-jumping class), and contribute four mitigations. Third, we specify a reproducible, containerised evalua-tion protocol aligned with the standardised testbeds now expected at top-tier venues-AutoPenBench, a Cybench subset, and the PentestGPT 182-sub-task benchmark-with multi-trial statistics (more than 10 trials per configuration, pass-at-k, non-parametric significance tests and effect sizes) and direct, same testbed reproduction of the PentestGPT and PentestAgent baselines rather than citation of their published numbers. On the legacy targets measured to date, the framework detected 26 services, enriched 34 CVEs, produced