Produce Whisker Formations on Metallic Fibers/Substrates and Strongly Adhering Catalysts for Filtration Applications

Technology #30280

Questions about this technology? Ask a Technology Manager

Download Printable PDF

Image Gallery
A scanning electron micrograph (50 scale) of 25 micrometer (f.lm) finely whiskered FeCrAlY fibers after 15 catalyst coating
Sudipta Seal, Ph.D.
Weifeng Fei, Ph.D.
Suresh Kuiry, Ph.D.
Managed By
Andrea Adkins
Assistant Director 407.823.0138
Patent Protection

Method for whisker formation on metallic fibers and substrates

US Patent 8,084,096 B1

Advanced catalyst system prepared from a whiskered aluminum-containing metallic alloy substrate

US Patent 8,247,034 B2

Method for whisker formation on metallic fibers and substrates

US Patent 8,591,996 B2

Method for whisker formation on metal fibers and metal surfaces for technical, medical and pharmaceutical applications.

The demand for higher quality materials, reduced manufacturing costs and environmentally clean processes is forcing industry to move away from traditional methods of separation and purification, such as distillation and pasteurization, towards the use of filtration. Currently utilized filter systems are capable of offering low energy, more efficient and environmentally friendly operations. Unfortunately, the widespread use of high performance filtration is restricted by the lack of suitable filter media materials. Such media must offer: low cost; durability; chemical resistance, particularly to acids and alkalis; resistance to high temperatures, for both operation and sterilization purposes; no particulation (i.e., release of filter media particles into the filtrate stream); mechanical strength to cope with pressure swings; separation efficiency, particularly for particles in the 0.1 to 100 microns range; and biocompatibility for certain applications such as the filtration of blood. Although the prior art provides many types of materials which remove, filter, or capture gases and particulate materials, these filters do not offer the efficiency, performance, and durability demanded by new, high performance applications. Mechanical methods of filtration typically operate by physical exclusion. A contaminated influent is passed through a porous medium that retains particles larger in size than that of the pores in the medium and permits passage of an effluent that contains particles smaller in size. There is a balance between capturing the smallest possible particles in the contaminated influent and the flow rate of the influent passing through the porous medium that must be achieved to provide high throughput. Moreover, the adherences of catalysts to these fibers are not reliable.

Technical Details

The present invention introduces a novel method for whisker formation on metallic fibers and substrates to greatly increase the total surface area of a metal alloy fiber or substrate medium. Catalytic coatings can then be easily and efficiently adhered to said substrates, providing dual benefits for filtration and catalytic activity. The fine whiskers greatly increase the total surface area of the fiber or alloy substrate medium to improve filtration efficiency, especially in terms of small particle removal. In addition, the whiskered fiber or substrate medium is a good host for the catalysts, which are useful in applications such as, hot gas cleaning and catalytic converters. Due to the existence of the fine whiskers, the adherence of the catalyst is greatly strengthened, which is useful in harsh environments where thermal shock or strong vibration is an issue.


  • Increases efficiency of filtration products
  • Process is versatile and efficient
  • Enables submicron filtration even under harsh environments where thermal shock or strong vibration is an issue
  • Inexpensive to produce
  • Resistant to chemical and high temperatures
  • Not subject to particulation
  • High in mechanical strength
  • Superior separation efficiency
  • Bio compatible


  • Cleaning exhaust gases:
  • Power plants
  • Petrochemical and chemical plants
  • Automobile catalytic converters
  • Filtration systems using particulate filter
  • Polymer filtration
  • Catalyst recovery burners
  • Industrial gas filtration
  • Liquid filtration
  • Catalyst and implant supports