Feasibility of AlCoCu decagonal quasicrystalline coatings obtained by High-Velocity oxygen fuel (HVOF)

•AlCoCu-based quasicrystalline (QC) coatings obtained via HVOF thermal spraying do not require post-spray heat treatment.•AlCoCu coatings are more feasible and cost-effective than AlCuFe quasicrystalline coatings with icosahedral structure.•AlCoCu coatings offer a promising, high-performance alternative for industrial protection in harsh environments.•Thermal stability and superior properties position these coatings for high-performance applications. Metallic coatings sprayed on ductile substrates play a crucial role in various industries by enhancing tribological properties and extending component durability, particularly in the automotive and aerospace sectors. Quasicrystalline coatings are notable for improving mechanical strength, wear resistance, and corrosion resistance. This study focuses on decagonal-symmetry quasicrystalline coatings produced from Al65Co18Cu17 powder using high-velocity oxygen fuel (HVOF) thermal spraying. The main objective was to achieve a coating predominantly composed of the decagonal-D quasicrystalline phase, as icosahedral-phase quasicrystals often decompose during thermal processing, necessitating costly additional treatments. The results showed that the coatings were mainly composed of the decagonal-D phase, with minor traces of m-Al13Co4 and B2-Al(Co,Cu) phases, eliminating the need for post-spray treatments. This advancement enhances cost-effectiveness and efficiency while maintaining the desirable properties of quasicrystals, such as high hardness and wear and corrosion resistance. The research concludes that AlCoCu (D) coatings are promising for harsh environments, offering a viable and high-performance alternative for industrial protection.