Abstract: Metallic bodies having discontinuously contacting sheet surfaces such as convolute-wound corrugated/non-corrugated metal sheet auto catalyst supports having metal-to-metal diffusion bonds formed at the contacting surfaces are provided. The diffusion bonds formed at the contacting surfaces are provided. The diffusion bonds are produced by heating the body in a non-oxidizing atmosphere, whereby metal from one surface diffuses into the metal from an adjacent surface. Some bonds may also be formed by welding. The bond-formation step may be performed in tandem with a subsequent step of oxidizing the sheet surfaces where they are not bonded, e.g. for making them into a more effectively-adhesive substrate for the catalyst they are to bear.

Abstract: A generally elliptical cylindrical metal substrate, and a method of construction thereof. A plate mandrel having a generally rectangular cross section is provided, and a first end of a web of metal substrate material is affixed to the plate mandrel. The metal substrate material preferably comprises alternate layers of planar metal foil and corrugated metal foil. As an alternative, a corrugated metal foil may be substituted for the planar foil. The metal substrate material web is wrapped around the mandrel, as by rotation of the mandrel while the web is fed off of a spool, until a substantially uniform thickness of metal substrate surrounding the mandrel is provided, a generally elliptical cylinder being formed. A second end of the web is affixed to a previous wrapping, thus forming a complete elliptical cylindrical metal substrate. The metal substrate is preferably catalyzed and used as a catalytic muffler or the like.

Abstract: A process for catalytic heat exchange which comprises providing a ceramic coated metal heat transfer membrane having two sides, one of which is catalytic, flowing a first gas over the catalytic side of the ceramic coated metal heat transfer membrane to generate heat, and flowing a second gas or vapor over the opposite side of the membrane whereby heat is transferred from the first gas to the second gas or vapor. Apparatus for carrying out the process is also disclosed.

Abstract: A catalyst comprising a metal or alloy substrate, an oxidation resistant coating applied to the substrate, the coating comprising aluminum metal powder in a ceramic binder, a high surface area catalytic washcoat over the oxidation resistant coating and a catalytically active material, e.g. a platinum group metal, associated with the washcoat.

Abstract: A method and apparatus for the ignition of a hydrocarbon gas stream utilizing a hydrogen pre-ignition arrangement. A small volume of hydrogen gas is mixed with air and directed past a platinum containing catalyst, e.g., activated with aluminum and in mesh form to heat the catalyst. A flame is produced and extends away from the catalyst and is directed from the catalyst so that it intersects a hydrocarbon gas stream and ignites the hydrocarbon gas stream at room temperature.

Abstract: A catalyst supporting structure comprising a plurality of catalytically active woven screens in a stacked relationship, the screens consisting essentially of a catalytically active alloy of iron, chromium, cobalt and aluminum.