Abstract Iron aluminides show great potential for use in high-temperature oxygen and sulfur environments, but the intermetallic phases of the Fe-Al system tend to be brittle. This paper describes a powder making process in which FeAl phases are reinforced with inclusions from other intermetallic phases that arrest cracks and prevent them from spreading. Thermally sprayed coatings produced from these SHS powders are analyzed with regard to their composition and structure. Paper includes a German-language abstract.