High-temperature catalyst for catalytic combustion and decomposition

A robust, high-activity catalyst for use in high-temperature decomposition of propellants, including 70-99% hydrogen peroxide, the catalyst comprising:

• about 30 to 50 weight percent of silver-palladium alloy;
• about 0 to 40 weight percent of manganese dioxide;
• about 0 to 40 weight percent of dysprosium oxide;
• and
• about 10 to 20 weight percent of alumina.

A method for forming a robust, high-temperature catalyst material for use in decomposing propellants or catalytic combustion in the power and propulsion industry, the method comprising:

• (a) forming a mixture of a plurality of constituents within a container, said mixture comprising:
• a first amount of an active catalyst material to a container, said first amount comprising between approximately 30 and 50 weight percent of the total weight of said mixture;
• a second amount of a co-catalyst promoter material to said container, said second amount comprising between approximately 20 and 40 weight percent of the total weight of said mixture;
• a third amount of a surface enhancer material to said container, said third amount comprising between approximately 10 and 20 weight percent of the total weight of said mixture;
• and
• (b) dry blending said mixture within said container to a uniform consistency.

A robust, high-activity activated catalyst for use in high-temperature decomposition of propellants, including 70-99% hydrogen peroxide, the activated catalyst comprising:

• a catalyst comprising about 30 to 50 weight percent of silver-palladium alloy, about 0 to 40 weight percent of manganese dioxide, about 0 to 40 weight percent of dysprosium oxide, and
• about 10 to 20 weight percent of alumina;
• and
• an activation treatment applied to said catalyst, said activation treatment comprising a noble metal loaded nitric add solution.

A method for forming a robust, high-temperature activated catalyst material for use in decomposing propellants or catalytic combustion in the power and propulsion industry, the method comprising:

• (a) forming a mixture of a plurality of constituents within a container, said mixture comprising:
• a first amount of an active catalyst material to a container, said first amount comprising between approximately 30 and 50 weight percent of the total weight of said mixture;
• a second amount of a co-catalyst promoter material to said container, said second amount comprising between approximately 20 and 40 weight percent of the total weight of said mixture;
• a third amount of a surface enhancer material to said container, said third amount comprising between approximately 10 and 20 weight percent of the total weight of said mixture;
• (b) dry blending said mixture within said container to a uniform consistency;
• (c) applying said mixture to a prepared substrate;
• and
• (d) activating said mixture to form an activated catalyst material.