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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.