Enhanced Adhesion Strength of Pt/γ-Al2O3 Catalysts on STS-444 Substrate via γ-Al2O3 Intermediate Layer Formation: Application for CO and C3H6 Oxidation

Pt/γ-Al2O3 catalysts coated on honeycomb-shaped stainless STS-444 steel substrates with a γ-Al2O3 intermediate layer were prepared using a conventional washcoating method. The intermediate layer was formed on the substrate surface through oxidation using pack cementation. The monolithic catalysts with the intermediate layer were fabricated for potential applications to pre-turbocharger catalysts, which suffer from severe conditions such as vibrations of the engine and high flow rates of exhaust gas. Adhesive strength tests and simultaneous oxidation reactions of CO and C3H6 were carried out for the Pt/γ-Al2O3 monolithic catalysts with and without the intermediate layer. The catalysts with an intermediate layer showed much stronger adhesion than the catalysts without an intermediate layer. Thus, the formation of a γ-Al2O3 intermediate layer by surface oxidation through pack cementation facilitated a significant enhancement of the catalyst adhesion strength without catalytic performance degradation.