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 Catalyst for the diminution of automobile exhaust gases

Details
Inventors: Ford, James A.; Butt, Sheldon H.;
Assignee: Olin Corporation (New Haven, CT)
Primary Examiner: Shine; W. J.
Assistant Examiner:
Attorney, Agent or Firm: Bachman; Robert H., Jackson; David A.

A catalyst for the diminution of automobile pollution and a method for forming the catalyst are described. The catalyst comprises a metal alloy substrate having a specified composition, an oxide layer containing a large proportion of alumina on the surface of the alloy and a surface layer comprising from 60 to 100% platinum and from 0 to 40% palladium.

DETAILED DESCRIPTION What is claimed is: 1.
A process for producing a catalyst for the removal of carbon monoxide and hydrocarbons from automobile exhaust gases comprising the steps of: A.
providing a substrate of a nickel base single-phase alloy comprising in solid solution 2 to 6% by weight aluminum and balance of 50 to 98% essentially of nickel, said alloy being capable of forming an adherent oxide layer mainly of aluminum oxide; B.
oxidizing the substrate alloy to produce the adherent alumina-rich layer at a temperature of from 350.
degree.
to 1,000.
degree.
F for a time of from 1 minute to 20 hours, said layer having a thickness of from 100 to 10,000 A; and C.
applying a layer of metal to the surface of the oxide layer, said layer having a thickness from 100 to 5,000 A and containing from .
001 to 40% palladium, from 0.
001 to 20% of a metal chosen from the group consisting of iridium, rhenium, osmium, ruthenium, and mixtures thereof, and balance essentially platinum.
2.
A process as in claim 1 wherein the thickness of the oxide layer is from 200 to 5,000 A.
3.
A process as in claim 1 wherein the oxidation step is performed at a temperature of from 500.
degree.
to 900.
degree.
C.
4.
A process as in claim 1 wherein the metal layer contains up to 20% palladium.
5.
A process as in claim 1 wherein the metal contains up to 5% of a metal chosen from the group consisting of iridium, rhenium, osmium, ruthenium, and mixtures thereof.
6.
A process as in claim 1 wherein the substrate alloy contains 2 to 6% aluminum, 0.
5 to 4.
0% silicon, 0.
001 to 6.
0% chromium, and balance essentially nickel.
7.
A process as in claim 6 wherein the substrate alloy contains 0.
001 to 1.
0% magnesium.
8.
A process as in claim 1 wherein the substrate alloy contains 4.
5% aluminum, 3% silicon, and 2% chromium.
9.
A catalyst for the diminution of automobile exhaust gases comprising: A.
a substrate alloy containing in solid solution 2 to 6% aluminum and balance of 50 to 98% essentially of nickel, said alloy being capable of forming an adherent oxide layer mainly of alumina; B



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