The irregular surface roughness morphology due to ultrasonic method was used approach for increasing the high surface area of substrate and catalyst. The purpose of this paper is to show the ultrasonic and nickel electroplating methods for NiO automotive catalyst development on FeCrAl substrate. The process began with pretreatment of FeCrAl using SiC and/or Al2O3 solution agitating by ultrasonic and followed with nickel electroplating. The oxidation test was conducted for developing the NiO. The physical morphology structure of the presence NiO on the FeCrAl substrate was analyzed using scanning electron microscope (SEM) in combination with energy dispersive X-ray spectroscopy (EDS). The cross sectional observation show the NiO catalyst completely existed on the FeCrAl. The ultrasonic method increases the irregular surface roughness morphology on FeCrAl substrate that influenced the homogeneous and stability of nickel electroplating and NiO surface area development.