Development of functionalized Fe–Al–Cr alloy fibers as innovative catalytic oxidation devices

Catalytic devices play a very important role to drastically reduce the noxious contaminants released by the combustion engines. Common devices consist of functionalized ceramic monoliths; an interesting alternative can be realized with a support material made of a high temperature compatible metal alloy, like FeCrAl. In the present study the FeAlCr fibers used to make a device similar to the ceramic monolith were thermally treated to obtain alumina whiskers, which were homogenously covered with alumina or ceria–zirconia–alumina washcoats. Pt or Pt and Pd have been loaded over the functionalized fibers obtaining an innovative oxidation catalyst. The systems were characterized by BET surface area measurements, hydrogen chemisorption and tested under high space velocity and fast heating run-up cycles, for hydrocarbon and CO conversion and particulate filtration ability. The good catalytic activity after severe aging treatments confirms the possibility of use of these innovative functionalized metallic stacks in air pollution control applications.