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The long-term durability of a ceramic racetrack converter is examined using the systems approach. Each of the converter components is characterized with respect to its behavior under simulated mechanical and thermal loads. In particular, the impact of three different washcoats on key physical properties, and the load vs. deformation characteristics of three different insulation mats are examined from mechanical and thermal durability point of view. Similarly, the can deformation at elevated temperature is taken into account to ensure adequate mounting pressure on ceramic monolith under all operating conditions. The temperature distribution at the midbed of the catalyst during engine dynamometer testing, together with the component properties data, are then used in a finite element model to compute thermal stresses in the monolith as function of engine load and speed.

The dynamic fatigue data for two different cordierite ceramic wall-flow diesel filter compositions, EX-54 and EX-66, are obtained at 200° and 400°C using the 4-point bend test. These compositions offer larger mean pore size and experience lower pressure drop than the EX-47 composition, and hence are more desirable for certain applications. Their fatigue behavior in the operating temperature range is found to be equivalent or superior to that of EX-47 composition which helps promote filter durability. The fatigue data are used to arrive at a safe allowable stress, which would ensure the required 290K vehicle mile durability. The paper also discusses the impact of mean pore size on high temperature strength and fatigue properties and their effect on filter durability.

The high temperature strength and deformation behavior of ceramic and two different metal substrates were measured in the 25°-1200°C temperature range in uniaxial and biaxial bending using rectangular bars and circular discs, respectively, prepared from the substrates. The data show that both of the metal substrates exhibit permanent deformation and lose their load carrying capability by an order of magnitude above 800°C. The ceramic substrate, on the other hand, preserves its strength and behaves elastically over the entire temperature range exhibiting neither permanent deformation nor cell distortion. These data suggest that the upper use temperature for metal substrates could be significantly lower than that for ceramic substrates to meet 50-100K vehicle mile durability