Direct DLP printing of Ni/Al2O3 catalysts with unrestricted geometry via a novel photosensitive aqueous slurry

Ni/Al 2 O 3 catalysts exhibit broad application prospects in energy field. However, Ni/Al 2 O 3 always faced inhomogeneous metal dispersion and weak metal-ceramic interfacial bonding. In this study, a novel aqueous photosensitive slurry was successfully developed for DLP 3D printing Ni/Al 2 O monolithic catalysts. Ni(NO 3 ) 2 ·6H 2 O as Ni source, Ni particles were in situ generated and firmly anchored onto Al 2 O 3 , which effectively prevent Ni particle migration and agglomeration, achieving nanoscale uniform distribution while strengthening the metal-ceramic interface. XRD, XPS and TEM were employed to characterize the phase, morphology, and surface chemical states of the catalyst. H 2 -TPR and chemisorption were further used to elucidated the reduction behavior and active metal dispersion. Activity tests showed that the DLP direct printing Ni/Al 2 O 3 monolithic catalyst achieved good CO conversion and excellent high-temperature thermal stability. This study provides both theoretical basis and experimental support for development of multifunctional composite slurry and promotes the advancement of “material-structure-function” integration in monolithic catalysts .