Abstract: A catalyst substrate comprises a substrate material having an inlet, an outlet, an opening therebetween to allow for the passage of exhaust gas therethrough, and further comprises a catalyst and a layer of zirconium phosphate. Catalyst substrates coated with zirconium phosphate exhibit improved thermal durability, improved thermal shock resistance, and improved alkali and acidic corrosion resistance.

Abstract: A method for manufacturing a planar sensor, comprises disposing a film of a material on a substrate, wherein the material is selected from the group consisting of platinum, rhodium, palladium and mixtures and alloys comprising at least one of the foregoing materials; annealing the material; measuring a resistance value of the material; laser trimming the annealed material; heat treating the laser trimmed material; and laser trimming the heat treated material to form the sensor.

Abstract: In one embodiment, a gas sensor element comprises: an electrolyte disposed between and in ionic communication with a first electrode and a second electrode; and a protective layer disposed adjacent to the first electrode. The protective layer comprises a catalytic coating comprising a reducible support material, a catalyst, and a water activator material. The catalyst coating is capable of converting an oxygen consuming species in a gas to an oxygen donating species.

Abstract: One embodiment of a method of operating a NOx abatement system comprises: introducing an exhaust stream to an ammonia generator in a normal flow direction, adsorbing NOx from the exhaust stream in the ammonia generator, diverting the exhaust stream around the ammonia generator, introducing hydrogen to the ammonia generator in a direction opposite the normal flow direction, and generating ammonia within the ammonia generator.

Abstract: In one embodiment, a ceramic device comprises: a ceramic substrate, a second substrate, and a bonding agent comprising a metal hydride disposed between the first ceramic substrate and the second ceramic substrate, wherein the metal hydride comprises a first metal selected from the group consisting of palladium, ruthenium, and combinations comprising at least one of the foregoing metals. In one embodiment, a method for making a ceramic device can comprise: disposing the bonding agent between a ceramic substrate and a second substrate to form an assembly and firing the assembly to a temperature above a liquid temperature of the bonding agent.

Abstract: A planar temperature sensing element is provided with first and second layers disposed over the temperature-sensing device. The second layer comprises an inorganic binder, a first ceramic material, and a second ceramic material. The inorganic binder is selected from the group consisting of M3+ phosphates, M4+ phosphates, M3+ nitrates, M4+ nitrates, and combinations comprising at least one of the foregoing. The first ceramic material is selected from the group consisting of aluminosilicate, M3+ aluminates, M4+ aluminates, M3+ hexaluminates, M4+ hexaluminates, and combinations comprising at least one of the foregoing. The second ceramic material comprises a phosphate-containing material.

Abstract: A catalyst for preferentially reducing carbon monoxide in a hydrogen stream. The catalyst is formed from a chemical composition including a hexaaluminate, a metal hydroxide and a precious metal. The composition may be disposed on a support or may be extruded or cast into or onto a support. Incorporation of hexaaluminates allows inclusion of metal hydroxides that flux the active precious metal surface at higher temperatures than can aluminum oxide-based catalytic compositions, thereby enhancing resistance of the catalyst and monolithic support and increasing the durability and thermal range of the PROX catalyst. An additional advantage is that lesser amounts of precious metal oxides need be deposited onto the hexaaluminate, while retaining activity similar to aluminum oxide compositions.

Abstract: In one embodiment, a method of making a sensor comprises: forming a slurry comprising a metal oxide, a binder, an acetate, and a reducing material, applying the slurry to at least a portion of a sensing element comprising two electrodes with an electrolyte disposed therebetween, and calcining the slurry to form a protective coating. In one embodiment, a gas sensor, comprises: a sensing element comprising a sensing electrode and a reference electrode having an electrolyte disposed therebetween, and a protective coating disposed over the sensing electrode, wherein the protective coating comprises aluminum oxide, an alpha alumina and about 2 wt % to about 15 wt % solid solution, based upon the total weight of the protective coating.

Abstract: A NOx abatement system comprising: a first NOx adsorber (18) capable of being disposed in-line and downstream of and in fluid communication with an engine (12); a selective catalytic reduction catalyst (20) disposed in-line and downstream of and in direct fluid communication with the first NOx adsorber (18), wherein the selective catalytic reduction catalyst (20) is capable of storing ammonia; and an off-line reformer (24) disposed in selective communication with and upstream of the first NOx adsorber (18) and the selective catalytic reduction catalyst (20), wherein the reformer (24) is capable of producing a reformate comprising primarily hydrogen and carbon monoxide.

Abstract: A reformer comprises a housing; a substrate disposed in the housing, wherein the substrate comprises a stabilized aluminate and a stabilized zirconate; and a catalyst disposed on the substrate.

Abstract: In one embodiment, an exhaust manifold can comprise: an exhaust conduit and a catalyst portion disposed within at least a portion of the exhaust conduit. The catalyst portion can comprise a metallic substrate, an aluminide layer disposed on at least a portion of the metallic substrate, and a catalyst material disposed on the aluminide. The catalyst material can be selected from the group consisting of platinum, palladium, ruthenium, rhodium, and combinations comprising at least one of the foregoing catalyst materials.

Abstract: In one embodiment, the exhaust manifold can comprise: an exhaust conduit having an inner surface, and an aluminide layer disposed on at least a portion of the inner surface of the manifold. In one embodiment, the method for making the exhaust manifold can comprise oxidizing aluminum on an inner surface of the manifold to form the aluminide layer.

Abstract: A ceramic device comprises a substrate; a resistive element disposed on the substrate; and a protective coating disposed on the resistive element, wherein the protective coating comprises a M+3 metal oxide, a M+4 metal oxide, or a combination comprising at least one of the foregoing, and a phosphate.

Abstract: In a solid-oxide fuel cell assembly comprising a plurality of components having electrically-conductive mating surfaces therebetween, the surfaces are sealed by an electrically insulating gasket that include a mineral composition comprising about 66 mol % MgO and about 33 mol % SiO2, the mineral composition being known mineralogically as forsterite. A brazing alloy may be applied to enhance bonding of the gasket into place. The gasket composition may include additions of Al2O3 to enhance electrical resistivity while having little to no impact of matching expansion coefficients of the gasket and metal mating surfaces. Also, additions such as titania or zirconia to inhibit glassy phase grain boundaries and the formation of impurities and pores in the ceramic grain boundaries may be used. A recommended particle size distribution of precursor powders is disclosed that leads to an optimum microstructure of the sintered gasket.

Abstract: In one embodiment, a coated article comprises a substrate with a coating comprising diamond like carbon layer, wherein the diamond like carbon layer comprising carbon and sulfur as terminal sulfur functional groups, wherein greater than or equal to about 70 wt % of the carbon present in the diamond like carbon layer comprises a sp3 carbon-to-carbon bond. The diamond like carbon layer has a concentration gradient such that the diamond like carbon layer on a side toward the substrate comprises a lower concentration of sulfur than a surface of the diamond like carbon layer disposed on a side of the layer opposite the substrate. The surface comprises about 0.1 at % to about 15 at % sulfur.

Abstract: A method for preparing an exhaust gas catalyst includes preparing a washcoat comprising a catalytically effective amount of at least one catalytically active metal disposed upon an oxide support; disposing the catalytically active metal-oxide support washcoat upon a catalyst substrate; drying the washcoated catalyst substrate using microwave energy to affix the precious metals to the oxide support; and conventionally calcining the dried washcoated catalyst substrate. The catalysts comprising a substrate having dispersed thereon an inorganic oxide washcoat, the washcoat having been affixed to the substrate by microwave drying, exhibit high exhaust gas purifying performance and long durability. The catalysts thus produced further provide a long in-service lifetime for reforming organic fuel species into hydrogen, carbon monoxide and light hydrocarbons used in the nitrogen oxides reduction process.

Abstract: An exhaust treatment device comprises a shell; a substrate disposed within the shell, the substrate having a catalyst disposed thereon, wherein the catalyst comprises platinum and a protective layer selected from the group consisting of tin oxide, iron oxide, and manganese oxide, and wherein the catalyst is capable of oxidizing greater than or equal to 50 wt. % carbon monoxide present in an exhaust gas stream at temperatures of about 150° C. to about 200° C.

Abstract: An exhaust emission control system can include a reformer a fuel source disposed upstream of and in fluid communication with the reformer, and a NOx adsorber disposed downstream of and in fluid communication with the reformer. The NOx adsorber can include a NOx adsorber catalyst having an acid adsorber disposed on the substrate and a base adsorber disposed over the acid adsorber.

Abstract: A catalytic converter system comprises an upstream catalytic converter comprising an upstream substrate having an upstream catalyst disposed thereon, wherein greater than or equal to 70 wt % of the upstream catalyst is disposed at a core of the upstream substrate, wherein the weight percent is based on a total weight of the upstream catalyst disposed on the upstream substrate.

Abstract: In one embodiment, an exhaust treatment device includes: a substrate, a shell disposed around the substrate, and a retention material disposed between the shell and the substrate. The substrate includes a catalyst that includes a precious metal and a solid solution comprising solid solution metals, wherein the solid solution metals include yttrium, zirconium, and titanium.