Make palladium in the channel of porous Alumina for catalyst use

A. How large are the pores in the alumina? Would it be easier to make the part you need from powdered palladium? There are several pressed metal companies to the north and northwest of PSU which could probably help you out.

aStandard impregnation with chemically resistant catalytic metals such as Palladium or Platinum is to dissolve in 3:1 Nitric / Hydrochloric acid mixture, neutralise as much as possible (and still avoid precipitation of the hydroxide), impregnate the matrix (alumina) and bake out the water. This should be repeated until satisfactory coverage is obtained. To avoid introducing alkali contaminants during the neutralisation process it would be better to neutralise with ammonia [on eBay or Amazon]. Watch it though; you need extraction, very slow dosing and protective gear as the process is, ahem, a little enthusiastic. Alternatively you may be able to obtain ready made solvated Palladium. Enquire from any reputable laboratory chemical supplier. A more technically difficult method is to generate Palladium sol by underwater electrical arcing and electrophoretically coat the alumina (1000V required to generate the necessary electrical field and some baking required after).