Patent ID: 8304030

Claim:
A method of providing different catalyst surfaces on the opposite surface sides of a metal substrate comprising: thermal spraying one surface of the substrate with a mixture of powders having a size greater than 10 micrometers and no more than 200 micrometers comprising 1) one or more than one of a hydroxide, carbonate, or nitrate of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and 2) one or more than one of a noble metal, noble metal hydroxide, noble metal carbonate, or noble metal nitrate onto the surface of the substrate such that the particles in the mixture decompose by pyrolysis to produce a mixture of, respectively on the one surface a distribution of particles of an oxide of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and particles of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold, such that the sprayed mixture results in particles bonded to the surface where approximately 90% have a size less than 5 microns (μm); and, subsequent to the thermal spraying, coating the surface of the substrate opposite the one surface by a physical vapor deposition process with one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold.