Catalyst coating deposition behavior by cold spray for fuel reforming

NiO/Al2O3 catalyst coatings on stainless steel and aluminum substrates, CuO/ZnO/Al2O3 catalyst coating on Al substrate have been prepared by cold spray technology for fuel reforming. Deposition behavior in coating formation has been studied. Microstructure and micro-region composition of the coatings are analyzed by SEM and EDX. Results show that the coating retains its original composition and majority porosity of catalyst feedstock. Smashing of the oxide feedstock particle plays an important role in coating formation. Original particle sizes and substrate materials affect bonding of the coating with substrate. Coke formation on NiO/Al2O3 coating is not so serious most likely due to good heat conduction. Bonding strength of CuO/ZnO/Al2O3 catalyst coating with Al mainly belongs to mechanical interlock and it seems lower than that of NiO/Al2O3 catalyst. First layer on CuO/ZnO/Al2O3 coating surface peels in reaction due to its fragile material nature. Conclusively, cold spray technology can be a successful method for functional catalyst coating fabrication for fuel reforming.