Dense metallic membranes, especially Pd and Pd alloys, have been intensely investigated to provide an alternative and economical way to obtain H
2
with ultrahigh purity. To overcome the high cost of Pd, composite membrane structures that comprise a thin layer of Pd are utilized. However, it is a challenge to obtain a thin, dense, and uniform Pd layer on the support materials. This study investigates the parametric analysis of γ-Al
2
O
3
interlayer formation and the electroless Pd plating (Pd ELP) procedures on α-Al
2
O
3
supports with the aim to achieve a thin, uniform Pd surface without annealing. Adjustments in PEG/PVA concentration, dipping time, and heat treatment enabled creating a thin γ-Al
2
O
3
interlayer on α-Al
2
O
3
, minimizing pore size and density. Hydrazine concentration, heat treatment, and bath temperature were adjusted to optimize Pd ELP to achieve maximum yield from the plating bath and a dense, uniform surface without annealing. Pd/γ-Al
2
O
3
/α-Al
2
O
3
structures were analyzed using scanning electron microscopy, X-ray diffraction, and thermogravimetric analysis to observe the impact of varied parameters on surface structures. Optimized sample was compared to an annealed Pd/α-Al
2
O
3
prepared in accordance with literature methods and a Pd/graphite/α-Al
2
O
3
sample to validate the use of optimized ELP procedure and the γ-Al
2
O
3
interlayer. Results show that a dense and uniform 13 μm Pd coating was achieved on a γ-Al
2
O
3
-coated α-Al
2
O
3
support without annealing, using three fresh ELP baths. This was done using sequential hydrazine addition with a decreased concentration (1 M) into the ELP baths at 30 °C, and applying heat treatment at 120 °C between each fresh ELP bath.