3Y-TZP strengthened ZrO2 ceramics were fabricated by using digital light processing (DLP) based additive manufacturing. The effects of 3Y-TZP concentration on the relative density, linear shrinkage, microstructure, and mechanical properties of the DLP-prepared ZrO2 ceramic were investigated in detailed. High precision ZrO2 ceramic parts with lattice structure with parts were successfully prepared by using DLP. The highest relative density and flexural strength were 96.40% and 306.53 ± 6.03 MPa, respectively, when the 3Y-TZP concentration was 7.5 vol%. The strengthening mechanism was discussed in detailed.

Digital light processing of 3Y-TZP strengthened ZrO2 ceramics

The present disclosure relates to a substrate comprising nanomaterials for treatment of gases, washcoats for use in preparing such a substrate, and methods of preparation of the nanomaterials and the substrate comprising the nanomaterials. More specifically, the present disclosure relates to a substrate comprising nanomaterial for three-way catalytic converters for treatment of exhaust gases.

Three-way catalytic converter using nanoparticles

Disclosed are, inter alia, methods of forming coated substrates for use in catalytic converters, as well as washcoat compositions and methods suitable for using in preparation of the coated substrates, and the coated substrates formed thereby. The catalytic material is prepared by a plasma-based method, yielding catalytic material with a lower tendency to migrate on support at high temperatures, and thus less prone to catalyst aging after prolonged use. Also disclosed are catalytic converters using the coated substrates, which have favorable properties as compared to catalytic converters using catalysts deposited on substrates using solution chemistry. Also disclosed are exhaust treatment systems, and vehicles, such as diesel vehicles, particularly light-duty diesel vehicles, using catalytic converters and exhaust treatment systems using the coated substrates.

Coated substrates for use in catalysis and catalytic converters and methods of coating substrates with washcoat compositions

A nanoparticle comprises a nano-active material and a nano-support. In some embodiments, the nano-active material is platinum and the nano-support is alumina. Pinning and affixing the nano-active material to the nano-support is achieved by using a high temperature condensation technology. In some embodiments, the high temperature condensation technology is plasma. Typically, a quantity of platinum and a quantity of alumina are loaded into a plasma gun. When the nano-active material bonds with the nano-support, an interface between the nano-active material and the nano-support forms. The interface is a platinum alumina metallic compound, which dramatically changes an ability for the nano-active material to move around on the surface of the nano-support, providing a better bond than that of a wet catalyst. Alternatively, a quantity of carbon is also loaded into the plasma gun. When the nano-active material bonds with the nano-support, the interface formed comprises a platinum copper intermetallic compound, which provides an even stronger bond.

Pinning and affixing nano-active material

Embodiments of present inventions are directed to an advanced catalyst. The advanced catalyst includes a honeycomb structure with an at least one nano-particle on the honeycomb structure. The advanced catalyst used in diesel engines is a two-way catalyst. The advanced catalyst used in gas engines is a three-way catalyst. In both the two-way catalyst and the three-way catalyst, the at least one nano-particle includes nano-active material and nano-support. The nano-support is typically alumina. In the two-way catalyst, the nano-active material is platinum. In the three-way catalyst, the nano-active material is platinum, palladium, rhodium, or an alloy. The alloy is of platinum, palladium, and rhodium.

Advanced catalysts for automotive applications

Yttria stabilized polycrystalline tetragonal zirconia (Y-TZP)–tungsten carbide (WC) composites were fabricated by hot pressing. Yttria (Y2O3) stabilizer content was kept at 3 mol% to ensure the phase structure of the Y-TZP composites to be tetragonal. To increase the moderate hardness of the 3 mol% Y2O3 added TZP structure, hard WC particles were added with various proportions up to 40 vol%. The TZP/WC composites were sintered at different sintering temperatures between 1450 and 1550 °C. The mechanical and microstructural properties of the resulting composites as well as the phase compositions were investigated. Reciprocating pin-on-disk tests were carried out to determine the wear behavior of the Y-TZP/WC composites. Using bi-modal WC reinforcement, the performance of the composite against wear was improved. Using dry wear sliding conditions under 55 N normal load and 45 km sliding distance, the worn volume of the 75 vol% nanosized – WC distributed 3Y-TZP/40WC composite was about 0.003 mm3.

Influence of WC particles on the microstructural and mechanical properties of 3 mol% Y2O3 stabilized ZrO2 matrix composites produced by hot pressing

Optimization of processing conditions and characterization investigations of ceramic injection molded and sintered ZrO2/WC composites

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Influence of WC particles on the microstructural and mechanical properties of 3 mol% Y2O3 stabilized ZrO2 matrix composites produced by hot pressing

Optimization of processing conditions and characterization investigations of ceramic injection molded and sintered ZrO2/WC composites