Development of Nanoporous Alumina Catalyst Support by Anodic Oxidation of Thermally and Kinetically Sprayed Aluminum Coa
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JTTEE5 22:138–144 DOI: 10.1007/s11666-012-9859-6 1059-9630/$19.00 ASM International
Development of Nanoporous Alumina Catalyst Support by Anodic Oxidation of Thermally and Kinetically Sprayed Aluminum Coatings K. Sakata, K. Tagomori, N. Sugiyama, M. Takenouchi, Y. Shinya, K. Morimoto, and Y. Suzuki (Submitted June 28, 2012; in revised form November 9, 2012) Of the various catalyst supports that have been developed, nanoporous alumina prepared by anodic oxidation of aluminum layers has attracted particular interest because of its extremely high specific area, easy controllability of porosity, coating thickness, and high bond strength with substrates. In the present study, kinetic- and plasma-spraying methods are employed to deposit aluminum, and the effect of the deposition method on the nanopore density after anodic oxidation is examined through scanning electron microscopy, transmission electron microscopy, and electron backscatter diffraction observations. It is found that nanopore densities in the kinetically sprayed aluminum layers are much denser than in plasma-sprayed layers. It is hypothesized that this is attributed to the dense dislocation because of large internal stress during the deposition process.
Keywords
aluminum, anodic oxidation, cold spray, microstructure, porosity, scanning electron microscopy, thermophotovoltaic, transmission electron microscopy
1. Introduction Green technologies are becoming increasingly important to reduce the environment burden. A high-performance catalyst layer would make a significant contribution for achieving this, because it could be used to reform hydrocarbon fuels, to remove toxic molecules such as carbon monoxide (CO) and ammonia (NH3) from exhaust gases, to reduce the formation of nitrogen oxide (NOx) in combustion, and to realize efficient conversion of chemical energy to thermal energy on a small scale (Ref 1-3). The ultimate goal of the present study is to develop hydroThis article is an invited paper selected from presentations at the 2012 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2012: Proceedings of the International Thermal Spray Conference, Air, Land, Water, and the Human Body: Thermal Spray Science and Applications, Houston, Texas, USA, May 21-24, 2012, Basil R. Marple, Arvind Agarwal, Laura Filofteia-Toma, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Andre´ McDonald, Ed., ASM International, Materials Park, OH, 2012. K. Sakata, K. Tagomori, N. Sugiyama, M. Takenouchi and Y. Shinya, Fujikikosan Corp, Kitakyushu, Japan; and K. Morimoto and Y. Suzuki, The University of Tokyo, Tokyo, Japan. Contact e-mail: [email protected].
138—Volume 22(2-3) March 2013
carbon-powered combustion-based microscale energy conversion systems (Ref 4, 5), including microscale thermophotovoltaic generation systems (Ref 6, 7) that can realize higher energy densities than lithium (Li)-ion batteries. Catalyst layers consist of the catalyst support and the
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