A comparison between traditional and in-situ alloyed thermal sprayed coatings for Catalytic Decomposition of Methane

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Pratidhwani Biswal, pratidhwani.biswal@igp.fraunhofer.de; Michél Hauer, michel.hauer@igp.fraunhofer.de; Dr. Andreas Gericke, andreas.gericke@igp.fraunhofer.de; Prof. Knuth-MichaelHenkel, knuth.henkel@uni-rostock.de; 

https://doi.org/10.53192/ITSC2026658

In this research work, thermal sprayed coatings are developed using wire arc spray process to function as catalytic coatings. Traditionally, pre-alloyed materials are used as feedstocks to produce thermal sprayed coatings of alloys. The main goal of this research work is to investigate and compare the coating characteristics and efficiency of traditional thermal sprayed coatings with in-situ alloyed thermal sprayed coatings for catalytic decomposition of methane under non-inert conditions and at a relatively lower catalyst activation temperature. Based on the promising preliminary results of twin-wire arc sprayed metal alloy coatings in facilitating methane decomposition at a lower activation temperature and without the need for an inert environment, a functional prototype incorporating these coatings is developed and tested, demonstrating the practical viability of the approach. Furthermore, the influence of spray parameters and coating characteristics on catalytic efficiency is studied and optimization of the coatings is performed accordingly.The Data are subsequently clustered based on their functional roles and process-related effects of individual parameters. The goal is to provide a comprehensive overview of critical interactions and recurring patterns. This paper finally identifies future research needs for systematic process control and optimization, with particular emphasis on trajectory planning to ensure reproducible thermal input.

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Erscheinungsdatum

March 2026

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8