Metal honeycomb substrates for chemical and thermal applications

An extruded metal honeycomb article comprising:

• a channeled metal body of unitary structure incorporating a two-dimensional array of parallel channels extending in a third dimension from a first end face to a second end face of the body, the channels being spaced to provide a honeycomb cell density of from 10 to 40 cells per square inch of honeycomb cross-section as measured transverse to the direction of the channels in the array;
• and
• interconnecting channel walls defining the channels, the channel walls being of a thickness in the range of about 0.001-0.1 inches from the first end face to the second end face of the body, being formed of a bulk metal having a porosity below 5% by volume, and being substantially free of channel wall discontinuities in directions transverse to the direction of honeycomb channel orientation in the article.