Nippon Steel Sumitomo Metal Corporation

Nippon Steel Chemical & Material Co., Ltd.

Nippon Steel & Sumikin Materials Co., Ltd.

Nippon Steel Corporation

Tooru Inaguma

Hiroaki Sakamoto

Shogo Konya

Miho Tomita

Youji Mizuhara

Yasuhiro Tsumura

Masayuki Kasuya

Shinji Kawasoe

Masafumi Omizu

Takuzo Kako

Motonori Tamura

Toshio Iwasaki

Adhesion of a catalyst layer and an oxide film in a honeycomb substrate for catalyst support is improved. A honeycomb substrate for catalyst support used in purification of exhaust gas includes a honeycomb body and an oxide film that is formed on the surface of the honeycomb body and that has &#x3b1;-alumina as a main component. The oxide film includes multiple oxide projections that are formed to be dispersed on the film surface and that include a contracted shape in which the width becomes narrower near the honeycomb body, and the density of the projection formations on the film surface is 0.20 (pieces/&#x3bc;m)-3.00 (pieces/&#x3bc;m).

Honeycomb substrate for catalyst support, and catalytic converter for exhaust gas purification

A base for supporting a catalyst for exhaust gas purification, the base including a honeycomb structure obtained by superposing a metallic flat foil and a metallic wavy foil, characterized in that the wavy foil has offset portions where any adjoining two of the wave phases arranged in the axial direction of the honeycomb structure are offset from each other. The base is further characterized in that an oxide coating film has been formed in a given range of these offset portions which includes exposed edge surfaces that are exposed on the gas-inlet side, that the oxide coating film includes 30-99.9 mass % first alumina, with the remainder comprising at least one of second aluminas, Fe oxides, and Cr oxides, that the first alumina comprises &#x3b1;-alumina, that the second aluminas comprise one or more of &#x3b3;-, &#x3b8;-, &#x3c7;-, &#x3b4;-, &#x3b7;-, and &#x3ba;-aluminas.

Metal substrate for catalytic converter and catalyst carrier

A metal substrate for catalytic converter for purifying an exhaust gas includes a honeycomb core with metal flat foil and corrugated foil stacked in layers, and an oxide film having a thickness of 0.1 &#x3bc;m or more and 10 &#x3bc;m or less is formed in a predetermined range including an exposed end surface exposed toward the gas inlet side. The oxide film contains at least a first alumina including &#x3b1;-alumina and a Fe oxide. The &#x3b1;-alumina contains &#x3b1;-alumina with solid-solved Fe and &#x3b1;-alumina with no solid-solved Fe. In the oxide film, the content of the first alumina is 30% by mass or more and 99.5% by mass or less, the content of the Fe oxide is 0.5% by mass or more and 40% by mass or less, and the content of Fe is more than 7% by mass and 35% by mass or less.

A honeycomb core for carrying a catalyst includes a flat metal foil and a corrugated metal foil, which are layered. The corrugated foil is configured by repeating a concavo-convex shaped part including a first top surface that is in contact with one of the flat foils, a second top surface that is in contact with another flat foil and is disposed at a position where the second top surface avoids the first top surface, and an inclined leg surface that has one end connected to the first top surface through a first bent part and another end connected to the second top surface through a second bent part, and extends in a direction inclined with respect to the first top surface and the second top surface, and has an offset part having different wave phases between front and rear in an axial direction of the honeycomb core.

Honeycomb core for carrying catalyst and catalytic converter

A metal substrate for catalytic converter is characterized by: a flat foil and a corrugated metal foil arranged on a gas inlet side end section being joined to each other; the flat foil and the corrugated metal foil arranged in an outer circumferential joining section being joined to each other, said outer circumferential joining section being connected to an end section of the gas inlet side end section in the axial direction; an outer jacket and the honeycomb core being joined by interposing a bonding layer in the gas outlet side end section area P fulfilling formula (A), when P is the length of the bonding layer in the axial direction; a corrugated metal foil having an impact mitigating section; the impact mitigating section being formed in an area corresponding to at least the gas inlet side end section and the outer circumferential joining section.2 mm&#x2264;&#x2264;50 mm&#x2003;&#x2003;(A):

Metal substrate for catalytic converters

A cast slab containing C: less than 0.02 mass % and made of an Fe-based metal of an &#x3b1;-&#x3b3; transforming component is subjected to hot rolling at a temperature of an A3 point or higher and is subjected to &#x3b1;-region rolling at a temperature of 300&#xb0; C. or higher and lower than the A3 point, and thereby a base metal sheet having a {100} texture in a surface layer portion is fabricated. Then, by performing a heat treatment under predetermined conditions, an Fe-based metal sheet is obtained in which a Z value is not less than 2.0 nor more than 200 when intensity ratios of respective {001}&#x3c;470&#x3e;, {116}&#x3c;6 12 1&#x3e;, and {223}&#x3c;692&#x3e; directions in a sheet plane by X-ray diffraction are set to A, B, and C respectively and Z=(A+0.97B)/0.98C is satisfied.

Fe-based metal sheet and manufacturing method thereof

On at least one surface of a base metal plate () of an &#x3b1;-&#x3b3; transforming Fe or Fe alloy, a metal layer () containing ferrite former is formed. Next, the base metal plate () and the metal layer () are heated to an A3 point of the Fe or the Fe alloy, whereby the ferrite former are diffused into the base metal plate () to form an alloy region () in a ferrite phase in which an accumulation degree of {200} planes is 25% or more and an accumulation degree of {222} planes is 40% or less. Next, the base metal plate () is heated to a temperature higher than the A3 point of the Fe or the Fe alloy, whereby the accumulation degree of the {200} planes is increased and the accumulation degree of the {222} planes is decreased while the alloy region () is maintained in the ferrite phase.

Fe-based metal plate and method of manufacturing the same

A cast slab containing C: less than 0.02 mass % and made of an Fe-based metal of an &#x3b1;-&#x3b3; transforming component is subjected to hot rolling at a temperature of an A3 point or higher and is subjected to &#x3b1;-region rolling at a temperature of 300&#xb0; C. or higher and lower than the A3 point, and thereby a base metal sheet having a {100} texture in a surface layer portion is fabricated. Then, by performing a heat treatment under predetermined conditions, an Fe-based metal sheet is obtained in which a Z value is not less than 2.0 nor more than 200 when intensity ratios of respective {001}&#x3c;470&#x3e;, {116}&#x3c;6 12 1&#x3e;, and {223}&#x3c;692&#x3e; directions in a sheet plane by X-ray diffraction are set to A, B, and C respectively and Z =(A+0.97B)/0.98C is satisfied.

The present invention provides an Fe&#x2014;Cr&#x2014;Al based stainless steel sheet and double layered sheet having a high Al content of greater than 6.5%, honeycomb bodies employing the stainless steel sheet or double layered sheet, and a process for fabrication of the steel sheet or double layered sheet. The sheet is a high Al-containing Fe&#x2014;Cr&#x2014;Al based stainless steel sheet or high Al-containing double layered sheet characterized by comprising, by weight, Cr: 10-30% and Al: &#x3e;6.5%-15%. Preferably, the steel sheet further comprises either or both Ti: 0.02-0.1% and Nb: 0.02-0.3%, and also comprises La: 0.01-0.1%, Ce: 0.01-0.1% and P: 0.01-0.05%. It also preferably comprises Cu: 0.01-1.0% by weight, and preferably further comprises Mg: 0.001-0.1% by weight. There is also provided a honeycomb body fabricated using the Fe&#x2014;Cr&#x2014;Al based stainless steel sheet.

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Tokyo, Japan

Tooru Inaguma