Patent ID: 8247034
Filing Date: 2012-08-21
Classification: B22F,C30B

Abstract:
1. A method of preparing an advanced catalyst system comprising the steps of: (a) selecting an aluminum-containing metallic alloy fiber having a diameter that ranges from approximately 12 microns to approximately 40 microns, wherein the metallic alloy composition is selected from the group consisting of MCrAlX, where M is at least one of iron (Fe), nickel (Ni) and cobalt (Co), Cr is chromium, Al is aluminum and X is at least one of yttrium (Y), zirconium (Zr), hafnium (Hf) and ytterbium (Yb); (b) applying a layer of hafnium oxide to coat the metallic alloy fiber; (c) heating the hafnium oxide coated metallic alloy fiber at temperatures from approximately 800° C. to approximately 1000° C. for a period of time between approximately 50 hours to approximately 200 hours to form a plurality of alumina whiskers on the surface of the metallic alloy fiber and transform gamma or theta alumina to alpha alumina thereby preserving the structural integrity of the metallic alloy and preparing a whiskered aluminum-containing metallic alloy substrate; and (d) depositing a catalyst layer on the whiskered aluminum-containing metallic alloy substrate using a dip coating technique to strongly adhere the catalyst layer to the whiskered substrate.