The focus of this work is on processes that lead to loss of active metal surface area during high temperature operation of automotive catalysts. As under-floor catalytic converters are moved closer to the engine to achieve faster light off, the catalyst is subjected to higher operating temperatures during the normal driving cycle. Sintering of the active metal phase leading to loss of surface area represents one of the most important factors limiting the long-term durability of automotive catalysts. Despite its obvious technological importance, fundamental understanding of sintering is still lacking.

In this research, we have prepared a series of Pd metal catalysts on a θ alumina support. The metal loading was varied from 1.1 wt% to 7 wt%. The catalysts were subjected to sintering at 900 °C for up to 192 hours. To ensure relevance to automotive catalysts, the sintering was performed in a gas atmosphere that contained 10 mol % H2O in flowing N2 or in air.