Recently, a metal support catalyst has been successfully developed and its use has been gradually increasing because of its advantages over the conventional ceramic support. The material properties required of an automotive catalytic converter are expected to increase in severity with intensifying environmental regulations on a worldwide level.
This study examined the material properties required of an Fe-Cr-Al alloy foil for a metal support having increased heat resistance. First, the effect of rare earth metals against high temperature oxidation resistance of the Fe-Cr-Al alloy foil is examined and the developed alloy is proposed. Second, the durability of the metal support is discussed. Third, the accelerated creep elongation caused by the growth of an oxide film when catalyst related material is loaded, is described and the influence on the performance of the metal support is discussed. Lastly, the material properties in order to improve the heat resistance of a metal support are discussed. As a result, it was found that the improvement of proof strength at high temperature is effective for improving the durability of a metal support concurrent with higher oxidation resistance.