Report developed under Small Business Innovation Research Contract. Under this Phase I SBIR contract, HY-Tech Research performed development of an abrasion resistant, non-stick coating for cookware used by the U.S. Army in the field. The deposition technique uses a vacuum arc source of elemental boron, a high-temperature material with excellent hardness, lubricity and chemical inertness. HY-Tech's boron arc source is based on the vacuum (cathodic) arc process, which produces the coating material by very efficient evaporation of the solid cathode. The Phase I project demonstrated that it is possible to deposit adherent coatings of amorphous boron on aluminum alloy substrates, even at high deposition rates (1 nm/s) and on surfaces that are not highly polished. The Phase I project successfully developed a deposition procedure for adhering boron to non-polished 3004A1 samples, as cut from a commercial roaster pan by varying the substrate bias program as well as substrate preparation. Microscopy indicated good adhesion to the substrate; however, tests in a high-salt environment led to delamination, suggesting that chemical bonding is weak or non-existent, which is consistent with our predictions.