Prosiding Pertemuan llmiah Ilmu Pengetahuan dan Teknologi Bahan 2002Serpong, 22 -23 Oktober 2002 lSSN 1411-2213

RESEARCH AND DEVELOPMENT PROGRAM FORCATALYTIC CONVERTER MATERIALS IN BATAN

Gunandjar, P. Untoro, Syahril and WuryantoNational Nuclear Energy Agency

Mampang Prapatan, Kuningan Barat, Jakarta 12710

ABSTRACT

Research and Development Program tor Catalytic Converter Materials is coordinated research program in tour main areastoward the development of catalytic converter systems over the next five fiscal years. The four areas are: concept development,human resources development, research tools & supporting development, and demonstration & technology base development.In order to meet the program mission and goals. research must be conducted on the sinergize of the intire catalytic convertersystem, including integration into the market applications. The total system must be designed properly to work togetherefficiently and reliability. To conduct systems studies and develop promising designs for succest"ull plan, it will be necessary tocoordinate the technical of various subsystems and components continously included the syntesis of catalyst and base materials,surtace treatments, modelling and simulation, testing and characterizations

INTRODUCTION

the various stages in atomic rearrangements andchemical reactions can be distinguished.

.High Temperature Corrosion to test the material atoperating conditions.

.Modelling and simulation to study physical andmechanical properties of the carrier.

PROGRAM MANAGEMENT

The Batan materials research program forcatalytic converter has been a succesful science andtechnology development program for a number ofreasons. These include consistent and continuousfunding, effective coordinated research program,flexibility to orient and refocus the research efforts inresponse to promising results or identified needs ofevery center, and establishment of partnerships andcollaborations with other institutions. (Figure 1).

The coordination research in the national fieldwill be connected with the national planning fromministry of research and technology and also withindustries to identify their needs and establish practicalgoals for technology development.

The program management strategy will beforwarded to reflect a new commitment to increase thecommercial impact of this program. BATAN's researchand development management strategy was changedfrom a technology push strategy to a market pull

strategy.

The research and development programdescribed in this paper is designed to facilitate andencourage research communities in the related field tomake use of the research facilities in Batan. By doingthis we hope that the communities can make a concertedeffort to address a specific issue; which in this case isthe research and development of materials for catalyticconverter. This program, which was begun in 1999, isone of the continuously funded materials developmentprograms ever undertaken at BAT AN and InternationalBuero from Ministry of Education and Research, FederalRepublic of Germany in the frame of bilateral cooperationresearch in science and technology for Developmentof Materials for .4utomotive Catalytic Converter IDN99/004. The Aachen University of Technology (GFERwth Aachen) and Juelich Research Center (RC Juelich)has provided facilities and consumable materials to thisprogram and expertise of the research cooperation.

The various research themas from syntesis untilprototipe production step are examined in detail andfor their adequacy to meet percieved future demands.Some examples of the developments emerging from ourreserch centers include the following:.Syntesis and development of metalic substrate

based on Fe, Al through casting, mechanicalalloying, and powder technology.

.Surface treatments and deposition technique usedto modify and improve the metal or ceramic subtrate.

.Structural Characterization with SEM/TEM(Scanning/Transmission Electron Microscope) andXRD (X Ray Diffraction) to monitor and analyseprocesses in materials on time scales so short that

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Research and Development Program/or CataLytic Converter Materials in BATAN (Gunandjar)

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Figure 1. Program management of the cooperation research

TECHNICAL PROGRAM

perfonnance, and modelling & simulation and propertiesand the strong interrelationship among them- thatdefine the field research work synergies.

The technical program should be well managed,with effective integration of the program elements -

from basic research through prototipe productiondemontrations and effective coordination of programgoals and responsibilities among participating researchinstitutions.

The technical research program has madesignificant technical advances since its inception frombasic research and applications. The early decission tofocus on sinergies all of diciplines in research centersand their relationships are shown schematically inFigure 2 in the form of a tetrahedron.

The field of catalytic converter research hasinvolved along many parallel and intertwined pathsassociated with wide ranges diciplines and R&Dlaboratories. It is these elements-syntesis and process,

Figure 2. A tetrahedron synergism program tor materials research and development

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(P3ls.IATAN)

Pro.~iding Pertemuan lbniah lbnu Pengetahuan don Teknologi Bahan 2002.s'erpong, 22 -23 Oktober 2002

ISSN 1411-2213

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Figure 3.1. Calculated stress distribution after cooling from 1200oC in the case of irregular oxide/metalinterlace given in Figure 3.11 a) for alumina scale on PM 2000 a) Stress in X direction; b) Stress in Y direction

Figure 3.2. Calculated stress distribution after cooling from l200oC in the case of convoluted scale morphologygiven in Figure 3.11 b) tor alumina scale on PM 2000 a) Stress in X direction; b) Stress in Y direction

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-Figure 4. Oxidation behaviour of implanted FeCrAI-foils of commercialalloy Aluchrom YHf at 1100.C in Ar-20%O, mixture

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Research and Development Program/or Catalytic Converter Materials in BATAN (Gunandjar)

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Figure 5. TEM-image from cross section and EDX analysis after lOOh isothermal oxidationat 1200.C in air

.Ion Implantation technique

.Ion Beam Mixing technique using cambinationbetween coating and ion bombardement technique

Characterization for physical, chemical andmechanical and also microstructure with electronmicroscopy technique:.Stress-strain behaviour in atmosphere and also

during heating.Thermal behaviour.High Temperature O.xidation at temperature < 11 00

°C in isothermal and zyclic conditions.SEMffEM coupled with crystallography analysis

Modelling and Simulation.Mechanical Modeling.Thermal modelling

FACILITIES AND SUPPORT

The main facilities for the programresponsibilities include facilities from various centersin BATAN or from other institutions. The facilities thathad been supported from BMBF in the frame ofcooperation will be used and optimized for further

Technical accomplishments in the syntesis anddevelopment of subtrate include:.The identification of processing technology.The determination of physical and mechanical

properties.The improvement of ductility by nricroalloying with

reactive elements.The improvement of elevated temperature strength

and processibility using standard alloyingtechniques, including solid solution strengthening,dispersion strengthening, weldability, and

castability.The preparing a catalyst is one important

process and should emphasize low cost processes \\"ithbig effort from national resources in Indonesia:.Metal e:\.1raction.Chemical reactions.Process optimation

Surface treatment using nuclear technique \\"ithion beam and coating technique:.Vacuum Coating, Plasma Coating and Sputtering

technique.Pack cementation technique

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Pro.siding Pertemuan Ilmiah lbnu Pengetahuan don Teknologi Bahan 2002.\'erpong. 22 -23 Okt()ber 2002 ISSN 1411-2213

Microstructural examination with TEM-EDXwith FIB (Focussed Ion Beam) cross section preparation(Figure 5) were used to study scale structure and moreprecisely locate the trace amount of elements in theoxide layer. The scale appeared to consist of columnargrains near the scale alloy interface and equiaxed grainsnear the oxide surface. The TEM investigations notonly allowed to locate grains of spinel (MgAI2O 4) at thetop of the oxide layer, but also magnesium at the grainboundaries of the alumina, whereas magnesium couldnot be identified within the alumina grains [7].

research tools connected with the program participatingcenters. Some results that has been produced usingthese facilities will be also be presented in this seminar.The support facilities are.MSB- TGA : Mass Suspension Balance -

Thermogravimetry Analyser.Software ANSYS 6.0 lite version.Dironond wire saw maschine.PIPS: Precision Ion Polishing System

Financial support will be obtained from BATANand other sources. However, it seems to me that a greatdeal of comnritment can be found on internal centers inBATAN. and also especially in connection with theactivities of RISTEK in the frame of IndonesianInternational Joint Research Program (RUTI). Anotherasset is the sustaining financial support from Germangovernment in the frame of bilateral cooperation in thescience and technology.

FUTURE FOCUS PROGRAM

PROGRESS

Technical activities started with a group fromalumni who have trained at GFE Rwth Aachen and RCJuelich.

Throughout the BAT AN material researchprogram, interaction with industrial participants will becritical to identify needs and priorities. Interactions withlocal industry will help BATAN to focus on optimizingalloy modifications and developing processtechnologies to meet industrial needs.

Future structure program in material researchshould be included 4 catagories of activities:.Human resources development and mobility in

contribution to national mobility programmes opento other institutions and support for teams of thehighest level of excellence.

.Research integrated infrastructures should beusable to support cross acces communicationinfrastructure and support for the development ofnew infrastructures/teams.

.Synergism and Networking in long-term and

multidisciplinary objectives implemented by ajointprogramme of activities.

.Science and people wellfare to bring the reserchcloser to people with a new form of dialogue,knowledge of science by citizens and youngscientist interesrt in spesific thema of materialresearch.

A working group, called "inteffiletalik" has beenfounded to design and execute ti}e program. Activitiesinclud: .

.Finite Element Modelling.Material syntesis.High Temperature Corrosion, including the activities

with nuclear technique monitoring for corrosion ofTLA (Thin Layer Activation), surface treatment andcorrosion testing with theffilogravimetry technique(The result will be also presented in this seminar).

.Characterization, a routine training or practicalworks in the field of newest characterizationmethods.

Some expermental results in Figure 3 [5] showsthe calculation of the stress distribution during coolingof oxidized commercial alloys from 1200 °C to 20 °C for5 ~m thick oxide scale on 100 ~m thick subtrate withANSYS. The stress distribution in X direction pointsout the tensile stress at the valleys and compressivestress at the ridges. In the Y direction the oxide stressis tensile with a value, which seems to the author toolow to cause initially oxide failure. Much higher tensilestress value is featured by the convoluted scale. Bothin X and Y direction, there are tensile stress areas withsignificant values of 0.5 -I GPa. Due to the oxideroughness the tensile stress areas appeared at ridges,but also in the oxide valleys. Therefore, the possibilityof oxide failure is greater by convoluted scale that bythe scale with an irregular oxide/metal interface.

The result of high temperature corrosionmeasurement with TGA measurements in Figure 4shows that the implanted sample with yttrium has thelower oxidation rate [6].

REFERENCES

[1).[2].

[3].[4].

[5].

[6J.

[7).

JAKSTRA. PUNAS RistekMATECK, Material Research Program fromGerman Ministry of Education and Research,

(1.998)Materials Program from Departemen of Energy

USA, (2001.)H. BODE, Materials Aspects in Automotive

Catal)1ic Converters, Wiley- VCH, (200 I)SUN.ARDI, Report during research in InstitutforMaterials and Processes in Energy System, (200 I. )W AGIYO, J ndonesian-Germany Seminar Report

IDN99/004, (2002)P. UNTORO et.al., Coluerence on MaterialAspects in Automotive Catalytic Converters,Muenchen,2001.

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Research and Development Program/or Catalytic Converter Materials in BATAN (Gunandjar)

TANYAJAWAB

Evvy Kartini, P3ffi -BATANPertanyaan1. Penelitian catalytic converter materials yang

dilakukan antar pusat daD antar instansi telahberjalan, apakah dapat memicu topik penelitianlainnya

JawabanI. Penelitian catalytic converter materiaL\" berjalan

karena didukung oleh para peneliti, sedangkanpejabat struktural hanya memfasilitasi saja. Tentusaja pola yang sarna dapat diterapkan untukpenelitian yang lain.

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