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Steel is the most commonly manufactured material in the world. Its performances can be improved by hot-dip coating with the low weight aluminum metal. The structure of the Al∥Fe interface, which is known to contain a buffer layer made of complex intermetallic compounds such as Al 5 Fe 2 and Al 13 Fe 4 , is crucial for the properties. On the basis of surface X-ray diffraction, combined with theoretical calculations, we derive in this work a consistent model at the atomic scale for the complex Al 13 Fe 4 (010)∥Al 5 Fe 2 (001) interface. The epitaxial relationships are found to be [130] Al 5 Fe 2 ∥[010] Al 13 Fe 4 and [1 1̅0] Al 5 Fe 2 ∥[100] Al 13 Fe 4 . Interfacial and constrained energies, as well as works of adhesion, calculated for several structural models based on density functional theory, identify the lattice mismatch and the interfacial chemical composition as main factors for the stability of the interface. Molecular dynamics simulations suggest a mechanism of Al diffusion to explain the formation of the complex Al 13 Fe 4 and Al 5 Fe 2 phases at the Al∥Fe interface.

A few low-order approximants to decagonal quasicrystals have been shown to provide excellent activity and selectivity for the hydrogenation of alkenes and alkynes. It is the case for the Al 13 Co 4 compound, for which the catalytic properties of the pseudo-2-fold orientation have been revealed to be among the best. A combination of surface science studies, including surface X-ray diffraction, and calculations based on density functional theory is used here to derive an atomistic model for the pseudo-2-fold o -Al 13 Co 4 surface, whose faceted and columnar structure is found very similar to the one of the 2-fold surface of the d -Al-Ni-Co quasicrystal. Facets substantially stabilize the system, with energies in the range 1.19-1.31 J/m 2 , i.e., much smaller than the ones of the pseudo-10-fold (1.49-1.68 J/m 2 ) and pseudo-2-fold (1.66 J/m 2 ) surfaces. Faceting is also a main factor at the origin of the Al 13 Co 4 catalytic performances, as illustrated by the comparison of the pseudo-10-fold, pseudo-2-fold and facet potential energy maps for hydrogen adsorption. This work gives insights toward the design of complex intermetallic catalysts through surface nanostructuration for optimized catalytic performances.