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An investigation into the design, development and evaluation of a “new” washcoat technology family that enables significant reductions in rhodium usage levels has been concluded. These findings were demonstrated on three vehicle applications utilizing different calibration A/F control strategies. Additional testing investigated optimal Rh placement on a two brick catalyst system and the impact on FTP and US-06 test cycles. This study concludes with an evaluation of full useful life aged catalysts tested on 6 and 8 cylinder applications that are shown to have met Bin 4 FFV and ULEVII emission standards.

In an effort to reduce hydrocarbon emissions for the upcoming vehicle emission regulations, FTP emissions were measured after the warm-up and underfloor converters using a four cylinder 2.3L 1991 engine on an auto-driver dynamometer stand. The warm-up and underfloor converter were located approximately 13 and 69 cm. respectively from the exhaust manifold. The warm-up and underfloor converter volumes varied from 0 - 2.67 liters. A total catalyst volume of 2.67 liters was distributed in 0.67 liter increments between the warm-up and underfloor converters. All of the converters were dynamometer aged appropriately with respect to their intended position in the exhaust system. Platinum/rhodium catalysts were evaluated in the underfloor location with platinum/rhodium or palladium containing catalysts in the warm-up location.

A parametric study was performed to investigate the interactions between Pd warm-up and underfloor converters on FTP emissions. Three different Pd warm-up converters were evaluated with six different underfloor converters on two different engines. The Pd warm-up converters primarily differed in the amount of ceria in the catalyst washcoat. These warm-up converters had a catalyst of 0.52 liters and a Pd loading of 100 g/ft3. The underfloor converters had a catalyst volume of 2.67 liters. Two Pt/Rh and one Pd catalyst technology were used in the underfloor converters. Each underfloor catalyst technology was investigated at two different loadings. The Pt/Rh underfloor converters were evaluated at 25 and 50 g/ft3 at a Pt/Rh ratio of 14/1. The Pd containing underfloor converters were evaluated at 50 and 100 g/ft3. All of the converters used in this study were dynamometer aged appropriately with respect to their intended position in the exhaust system.

FTP and ECE + EUDC emissions are measured from six converters having similar restriction and platinum group metals on two 1999 prototype engines/calibrations. A 2.2L four cylinder prototype vehicle is used to measure FTP emissions and an auto-driver dynamometer with a prototype 2.4L four cylinder engine is used to determine the ECE + EUDC emissions. The catalytic converters use various combinations of 400/3.5 (400cpsi/3.5mil wall), 400/4.5, 400/6.5, 600/3.5, 600/4.5, and 900/2.5 ceramic substrates in order to meet a restriction target and to maximize converter geometric surface area. Total catalyst volume of the converters varies from 1.9 to 0.82 liters. Catalyst frontal area varies from 68 cm2 to 88 cm2. Five of the six converters use two catalyst bricks. The front catalyst brick uses either a three-way Pd washcoat technology containing ceria or a non-ceria Pd washcoat technology. Pd loadings are 0.1 troy oz. of Pd.