Patent ID: 8591996
Filing Date: 2013-11-26
Classification: B22F,C30B

Abstract:
1. A method for forming whiskers on the surface of an aluminum-containing metallic alloy substrate comprising the steps of: selecting an aluminum-containing metallic alloy fiber is selected from the group consisting of MCrAIX, where M is at least one of iron (Fe), and cobalt (Co) in a range of approximately 60% to approximately 70%, Cr is chromium in a range of approximately 20% to approximately 30%, Al is aluminum in a range of approximately 5% to approximately 10% and X is at least one of yttrium (Y), zirconium (Zr), hafnium (Hf) and ytterbium (Yb) in a range of approximately 0.05% to approximately 0.15%; applying a hafnium oxide layer to coat the metallic alloy fiber; heating the hafnium oxide coated metallic alloy substrate at oxidation temperatures and for a period of time to form alumina whiskers on the surface of the hafnium oxide coated metallic substrate; and depositing a catalyst layer on the whiskered surface using dip coating with at least one catalysts selected from platinum, rhodium and a multicomponent sol with one of alumina, zirconia, and ceria increasing the total surface area of the metallic alloy substrate during oxidation.