A method to form well-adhered γ-Al2O3 layers on FeCrAl metallic supports

Well-adhered γ-Al2O3 coating layers can be formed on FeCrAl metallic supports for the preparation of structured catalysts in diesel particulate filter (DPF) systems using a three-step method—pre-oxidation, primer deposition and coating deposition. The optimal pre-oxidation is at 950 °C for 10 h; the optimal primer sol calcination is at 800 °C for 3 h; and the optimal γ-Al2O3 slurry calcination is at 900 °C for 2 h. If the oxidation temperature is 1050 °C, only 0.5 h is required to obtain almost the same coating adhesion level as at 950 °C for 10 h. The data concerning effects of the major preparation parameters (the pre-oxidation time, temperature, primer calcination temperature and the coating calcination temperature) are presented herein. The coating adhesion was measured by ultrasonic adhesion, thermal shock and interface shear strength tests.