Catalyst coating deposition behavior by cold spray for fuel reforming.

NiO/Al 2 O 3 catalyst coatings on stainless steel and aluminum substrates, CuO/ZnO/Al 2 O 3 catalyst coating on Al substrate have been prepared by cold spray technology for fuel reforming. Deposition behavior in coating formation has been studied. Microstructure and micro-region composition of the coatings are analyzed by SEM and EDX. Results show that the coating retains its original composition and majority porosity of catalyst feedstock. Smashing of the oxide feedstock particle plays an important role in coating formation. Original particle sizes and substrate materials affect bonding of the coating with substrate. Coke formation on NiO/Al 2 O 3 coating is not so serious most likely due to good heat conduction. Bonding strength of CuO/ZnO/Al 2 O 3 catalyst coating with Al mainly belongs to mechanical interlock and it seems lower than that of NiO/Al 2 O 3 catalyst. First layer on CuO/ZnO/Al 2 O 3 coating surface peels in reaction due to its fragile material nature. Conclusively, cold spray technology can be a successful method for functional catalyst coating fabrication for fuel reforming. [ABSTRACT FROM AUTHOR]