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Well-adhered gamma-Al2O3 coating layers can be formed on FeCrAl metallic supports for the preparation of structured catalysts in diesel particulate filter (DPF) systems using a three-step method-pre-oxidation, primer deposition and coating deposition. The optimal pre-oxidation is at 950 degreesC for 10 h; the optimal primer sol calcination is at 800 degreesC for 3 h; and the optimal gamma-Al2O3 slurry calcination is at 900 degreesC for 2 h. If the oxidation temperature is 1050 degreesC, only 0.5 h is required to obtain almost the same coating adhesion level as at 950 degreesC for 10 h. The data concerning effects of the major preparation parameters (the pre-oxidation time, temperature, primer calcination temperature and the coating calcination temperature) are presented herein. The coating adhesion was measured by ultrasonic adhesion, thermal shock and interface shear strength tests. (C) 2002 Elsevier Science B.V. All rights reserved.