DOC Metal Substrate

Why FeCrAl Is the Preferred Material for DOC Metal Substrate Manufacturing

In a DOC Metal Substrate, material choice is not just a technical detail — it directly determines durability, coating stability, and long-term performance. That’s why most metal substrates used in diesel oxidation catalysts are made from FeCrAl alloy (iron–chromium–aluminum).

FeCrAl stands out because of its exceptional resistance to high temperatures. In real operating conditions, exhaust temperatures can easily reach 700–900°C, especially in heavy-duty and industrial engines. Standard stainless steels tend to degrade or scale under these conditions, but FeCrAl forms a stable aluminum oxide layer on its surface. This layer protects the metal from further oxidation, helping the DOC Metal Substrate maintain its structure even after thousands of thermal cycles.

Another key advantage is excellent adhesion for catalyst coatings. The natural oxide film created by FeCrAl provides an ideal surface for the washcoat to bond with. This improves the durability of the catalytic layer and reduces the risk of peeling or flaking under vibration — a common problem in off-road, marine, and construction equipment.

FeCrAl is also known for its mechanical strength and fatigue resistance. When formed into honeycomb structures, the thin metal foils must handle constant vibration, pressure changes, and engine pulses. FeCrAl maintains its strength even in thin gauges, making it perfect for lightweight yet strong honeycomb designs in DOC Metal Substrate applications.

In short, FeCrAl is used because it offers the right balance of heat resistance, oxidation protection, coating compatibility, and mechanical durability — all of which are essential for a reliable, long-lasting DOC Metal Substrate in demanding diesel environments.