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Canning is a very important aspect in the catalyst converter design, especially with the current trend of using more thin wall and ultra-thin wall substrates. This paper systematically investigated canning issues at different stages of converter manufacturing processes and operations. Commonly used converter canning processes, which include traditional clamshell style and tourniquet wrap, are included in the studies. Using a previously developed mat material model, visco-elastic behavior, as well as the unique expansion characteristic of the intumescent mat under high temperature, are included in the simulations. Lab testing of the mat material at different loading speeds was conducted to obtain the visco-elastic properties. These will allow the studies of the effect of closing speed on the peak pressures during canning processes, as well as the pressures during heating and cooling.

Virtual validation of the dynamic performance of exhaust systems with measured vehicle loads is being used increasingly by many OEM's and exhaust system suppliers. The loads induced due to power train roll motion, the vibration characteristic from the ground and power train system are collected during the RLDA (Road Load Data Acquisition). Modal transient dynamic analysis is carried out using FEA with input loading from the full event RLDA to predict the behavior of the system. The key performance measures that are studied in this work are the force transmitted by the exhaust system to the vehicle body and the damage at the critical joints. There are many design variables that could impact the dynamic response of the system like the choice of the isolator, the thickness of the parts, the weld characteristics of joints etc. Inherent variability in the vibration data obtained during RLDA could also influence the behavior of the exhaust system.