Quasicrystals are materials whose structure cannot be understood within classic crystallographic methodology. Quasiperiodic structures have a long-range orientation order but lack transitional periodicity. This non-periodic structure gives quasicrystals a unique range of physical properties including: poor thermal conductivity; excellent crystallographic stability up to their melting point; can be thermally sprayed to display either wear resistant or abradable characteristics; possess excellent release properties (low coefficient of friction); and, they are non-work hardenable. This effort describes parametric conditions utilized to deposit coatings of identical parent metal chemistry but with vastly different end properties.

Ni+Al, Ti+Al, NiCr+AI, and Cr+Al powders react exothermically in the heat zone of thermal spraying systems. Whether such reactions occur between aluminum and superalloy powders is the underlying question of this study. This paper describes composites of this nature and their sprayability to form adherent, metallurgically bonded deposits. Through parametric manipulation, coatings can be produced with a range of properties from dense to open (porous/abradable) structures. The paper also shows how seed particles can be clad with aluminum and sprayed to predictable property limits.