Gm Global Technolgoy Operations, Inc.

Terrence B Boyer

Raymond E Bedford

Nancy Jean Paulus

The invention includes a metal substrate having an insulative coating thereon, wherein the insulative coating is prepared from a composition including .gamma.-alumina (gamma alumina) with a wide particle size distribution that includes at least 10 percent of the particles having by weight being larger than 20 micrometers, 5 to 10 percent by weight pseudo-boehmite, and a catalyst. The composition is sprayed onto the metal substrate at a distance from about 12 to about 15 inches using a round orifice spray nozzle operated at a pressure ranging from about 15 to about 25 psi. A polyvinyl alcohol overcoat is applied to the insulative coating to prevent flaking and chipping when coated metal substrate are stacked on each other. The insulative coating is particularly useful on folded foils used to construct metal monoliths for electrically heating catalytic converters.

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Davison, MI, United States of America

Terrence B Boyer