Characterization of a commercially produced Al–Cu–Fe–Cr quasicrystalline coating

A commercially produced Al–Cu–Fe–Cr thermal spray cookware coating was characterized. Gas-atomized powders with a nominal composition of Al71Cu10Fe8.5Cr10.5 were apparently used to form the coatings. The coating is very uniform and contains a quasicrystalline icosahedral phase along with a second phase that is either a quasicrystalline decagonal phase or its nearly identical crystalline approximant. The phases show evidence of structural imperfection and appear to be in a highly transitional state, which is likely caused by the rapid cooling during thermal spraying. A large fraction of unmelted particles and microcracks were observed throughout the coating.