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Mechanical Properties Testing of Catalyst Layer

The catalyst support is generally used to disperse the catalyst material to increase the contact area of the reaction. In a catalytic converter, a coating called a catalyst layer contains a catalyst carrier and a catalytically active material. In view of the role of the catalyst layer in the catalytic converter, its mechanical strength is very important because it determines the service life of the catalytic converter.

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Based on different measurement principles, Alfa Chemistry Catalysts provides a variety of methods for measuring the strength of the catalyst layer, and provides you with reliable analysis and reports on the mechanical performance of the catalyst layer. Our professional chemists can recommend suitable test solutions for customers to perfect your catalyst project.

Alternative Test Methods

  • The strength of the catalyst layer is measured based on the mass loss of samples exposed to certain test environments. Such test methods include ultrasonic vibration test, simulated environment test (high-speed hot air flow), thermal shock test, drop test and abrasive test.

Mechanical Properties Testing of Catalyst LayerFigure 1. Schematic diagram of ultrasonic vibration and simulated environment tests. [1]

  • Reflect the strength of the catalyst layer based on the stress or the work done, and make a more direct measurement of the bonding strength between the particles in the catalyst layer. Such test methods include pull-off test and scratch test.

Mechanical Properties Testing of Catalyst LayerFigure 2. Schematic diagram of the pull-off and scratch tests. [1]


  • Researchers have developed a method to form a well-adhesive γ-Al2O3 layer on FeCrAl metal support for the preparation of structured catalysts in diesel particulate filter (DPF) systems. In this work, the adhesion of the catalyst coating is measured by ultrasonic, thermal shock and interfacial shear strength tests.

Mechanical Properties Testing of Catalyst LayerFigure 3. The surface morphology of the coated sample after the ultrasonic adhesion test.[2]

  • The abrasion performance of the sol-gel alumina coating on the chemically pretreated mild steel substrate was evaluated by the abrasion tester. Two main body (high stress) abrasive wear tests were performed to measure the wear resistance of the coating. The experimental results show that the pre-phosphated alumina coated sample has significantly higher wear resistance than the alumina coated sample without pre-phosphated.

Mechanical Properties Testing of Catalyst LayerFigure 4. The relationship between weight loss and sliding distance of mild steel (MS), pre-phosphated alumina coated mild steel (coated MS with phosphating), and alumina coated mild steel (coated MS).[3]


  1. Jiankai Yang. (2019). "A Review of Measurement Techniques of Mechanical Properties of the Catalyst Layer in Catalytic Converters", Johnson Matthey Technol. Rev. 63(3): 177-190.
  2. Su Zhao. (2003). "A method to form well-adhered γ-Al2O3 layers on FeCrAl metallic supports", Surface and Coatings Technology 167(1): 97-105.
  3. Gazala Ruhi. (2006). "Wear and electrochemical characterization of sol-gel alumina coating on chemically pre-treated mild steel substrate", 201(3-4): 1866-1872.
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