3D X-ray tomography visualization of catalyst distribution in open-cell foam.

Unlocking Catalyst Uniformity: How 3D X-ray Tomography is Revolutionizing Material Science

Mira Elwood in Tech & Innovation August 2025 • 4 min read.

"Explore how advanced imaging techniques are transforming the development of efficient and reliable catalytic converters, paving the way for cleaner technologies."

For decades, monolithic catalysts have played a crucial role in industries ranging from automotive to chemical processing. More recently, open-cell foams have emerged as promising alternatives, offering improved mass and heat transfer capabilities. To harness the full potential of these foams, it’s essential to coat them with a catalytic layer – a process often achieved through dip-coating.

The dip-coating method involves immersing the foam into a liquid suspension, followed by the critical step of removing excess liquid to create a thin, uniform coating. The challenge lies in achieving this uniformity, as inconsistencies can significantly impact catalytic performance. Recent advancements in 3D X-ray tomography have provided a powerful tool to assess and optimize these coatings.

This article explores how 3D X-ray tomography, coupled with image analysis, is revolutionizing the way researchers analyze catalyst distribution within open-cell foams. By visualizing the spatial localization of the catalytic layer, scientists can now fine-tune coating methods to achieve unprecedented levels of uniformity, leading to more efficient and reliable catalytic reactors.

The Power of 3D X-ray Tomography

3D X-ray tomography visualization of catalyst distribution in open-cell foam.

3D X-ray tomography offers a non-destructive method to visualize the internal structure of materials in three dimensions. In the context of catalyst coatings, this means researchers can see exactly how the catalytic layer is distributed throughout the foam structure, identifying areas of over-coating, under-coating, or uneven distribution. This level of detail is simply not possible with traditional methods.

The process involves taking numerous X-ray images of the sample from different angles and then using sophisticated software to reconstruct a 3D model. This model can then be analyzed to quantify the thickness and distribution of the catalyst layer. The resulting data provides invaluable insights for optimizing the coating process.

Key Advantages of 3D X-ray Tomography:

Non-destructive analysis preserves the sample for further testing.
Provides detailed 3D visualization of catalyst distribution.
Enables quantitative measurement of coating thickness and uniformity.
Facilitates optimization of coating methods for improved performance.

One study highlighted in the original research compared different methods for removing excess liquid during the dip-coating process. These methods included simple air blowing, axial air blowing within a tube, and spin-drying/centrifuging. The results showed that simple air blowing tended to produce non-uniform coatings, with catalyst accumulating in certain areas while leaving others under-coated. In contrast, axial air blowing within a tube offered more consistent results.

Looking Ahead

As the demand for more efficient and sustainable technologies grows, the importance of optimizing catalytic processes will only increase. 3D X-ray tomography provides a powerful tool for achieving this optimization, enabling researchers to develop catalysts with improved performance, durability, and reliability. By unlocking the secrets of catalyst uniformity, we can pave the way for cleaner air, more efficient chemical processes, and a more sustainable future.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.3390/chemengineering2040052, Alternate LINK

Title: Demonstration Of The Use Of 3D X-Ray Tomography To Compare The Uniformity Of Catalyst Coatings In Open-Cell Foams

Subject: General Energy

Journal: ChemEngineering

Publisher: MDPI AG

Authors: Marie-Line Zanota, Stéphanie Pallier, Anaïs Dousse, Joël Lachambre, Valérie Meille

Published: 2018-10-30

Everything You Need To Know

What exactly is 3D X-ray tomography, and how does it help in analyzing catalyst coatings on open-cell foams?

3D X-ray tomography is a non-destructive imaging technique that allows researchers to visualize the internal structure of materials in three dimensions. In the context of catalyst coatings on open-cell foams, it enables the detailed observation of how the catalytic layer is distributed throughout the foam's structure. This allows the identification of areas with over-coating, under-coating, or uneven distribution, which is not possible with traditional methods. The process involves capturing numerous X-ray images from various angles and using software to reconstruct a 3D model, which is then analyzed to measure the thickness and uniformity of the catalyst layer.

Why are open-cell foams gaining attention as catalysts, and why is the uniformity of their catalytic coating so important?

Open-cell foams are emerging as promising alternatives to monolithic catalysts due to their improved mass and heat transfer capabilities. To utilize their potential, these foams must be coated with a catalytic layer, often through a dip-coating process. The uniformity of this coating is essential because inconsistencies can significantly impact the overall catalytic performance. Achieving uniform coatings ensures that the catalyst material is evenly distributed throughout the foam structure, maximizing its surface area and reactivity.

Can you explain how the dip-coating method is used to apply a catalytic layer to open-cell foams, and what challenges exist in achieving a uniform coating?

The dip-coating method involves immersing open-cell foams into a liquid suspension containing the catalytic material. The crucial step is removing excess liquid to create a thin, uniform coating. Achieving uniformity is challenging, and different techniques for removing excess liquid can impact the final coating quality. For instance, simple air blowing can lead to non-uniform coatings, whereas axial air blowing within a tube tends to produce more consistent results. 3D X-ray tomography plays a crucial role in assessing the effectiveness of these different methods.

According to research, what are the different methods for removing excess liquid during dip-coating, and how do they affect the uniformity of the catalyst coating?

One study compared different methods for removing excess liquid during the dip-coating process, including simple air blowing, axial air blowing within a tube, and spin-drying/centrifuging. Simple air blowing often resulted in non-uniform coatings, with the catalyst accumulating in certain areas while leaving others under-coated. Axial air blowing within a tube provided more consistent results. 3D X-ray tomography allowed researchers to visualize and quantify these differences, providing valuable insights for optimizing the coating process. This highlights the importance of selecting the appropriate method to achieve uniform catalyst distribution.

What are the broader implications of optimizing catalytic processes using 3D X-ray tomography for creating more efficient and sustainable technologies?

By optimizing catalytic processes through techniques like 3D X-ray tomography, we can improve the performance, durability, and reliability of catalysts. This has significant implications for creating more efficient and sustainable technologies, such as cleaner air in automotive applications and more efficient chemical processes in various industries. Uniform catalyst distribution ensures maximum surface area and reactivity, leading to better conversion rates and reduced waste. This is vital for industries that rely on catalysis for chemical transformations and environmental protection.