Washcoat Deposition of Ni- and Co-ZrO2 Low Surface Area Powders onto Ceramic Open-Cell Foams: Influence of Slurry Formulation and Rheology

Abstract: The effect of formulations and procedures to deposit thin active layers based on low surface area powders on complex geometry substrates (open-cell foams) was experimentally assessed. An acid-free liquid medium based on water, glycerol, and polyvinyl alcohol was used for powder dispersion, while a dip-coating technique was chosen for washcoat deposition on 30 PPI ceramic open-cell foams. The rheological behavior was explained on the bases of both porosity and actual powder density. It was proved that the use of multiple dippings fulfills flexibility requirements for washcoat load management. Multiple depositions with intermediate flash drying steps at 350 °C were carried out. Washcoat loads in the 2.5 to 22 wt. % range were obtained. Pore clogging was seldom observed in a limited extent in samples with high loading (>20 wt. %). Adhesion, evaluated by means of accelerated stress test in ultrasound bath, pointed out good results of all the deposited layers.