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For decades, ceramic fiber mats have been used to mechanically support substrates in catalytic converters. Intumescent mats, those that expand with heat, are composed primarily of ceramic fibers, vermiculite, and organic binder. The binder is required for manufacturing, handling, and installation. Unfortunately, under cool operating conditions, its effects on mat performance are often negative. While residual binder is not an automatic precursor to premature failure, it can amplify the effects of other factors such as gap control and vibration. As the mat mount material is heated, sections can become soft and pliable. In the absence of sufficient heat for complete binder removal, regions of the mat may become rigid during the cooling cycle. This results in a decrease in mat resiliency. Several tests can be used to show the relationship between binder level and material performance. These tests typically characterize expansion properties and pressure performance.

Mobile source emissions standards are becoming more stringent and particulate emissions from gasoline direct injection (GDI) engines represent a particular challenge. Gasoline particulate filter (GPF) is deemed as one possible technical solution for particulate emissions reduction. In this work, a study was conducted on eight formulations of lubricants to determine their effect on GDI engine particulate emissions and GPF performance. Accelerated ash loading tests were conducted on a 2.4L GDI engine with engine oil injection in gasoline fuel by 2%. The matrix of eight formulations was designed with changing levels of sulfated ash (SASH) level, Zinc dialkyldithiophosphates (ZDDP) level and detergent type. Comprehensive evaluations of particulates included mass, number, size distribution, composition, morphology and soot oxidation properties. GPF performance was assessed through filtration efficiency, back pressure and morphology.

This experimental work focuses on defining the detailed morphology of secondary emission products derived from the combustion of cerium (Ce) fuel-borne catalyst (FBC) doped with diesel fuel. Cerium is often used to promote the oxidation of diesel particulates collected in diesel aftertreatment systems, such as diesel particulate filters (DPFs). However, it is suspected that the secondary products could be emitted from the vehicle tailpipe without being effectively filtered by the aftertreatment systems. In this work, these secondary emissions were identified by means of a high-resolution transmission electron microscope (TEM), and their properties were examined in terms of morphology and chemistry. In preparation for fuel doping, a cerium-based aliphatic organic compound solution was mixed with a low-sulfur (110 ppm) diesel fuel at 50 ppm in terms of weight concentration.

Helmholtz resonator has been used in industry for a long time to reduce the noise from exhaust system in vehicle or machinery. Numerous investigations have been done in the past to study the effect of a Helmholtz resonator connected to a pipeline. A general procedure for the analysis of curved or flat, thin two dimensional gas cavities such as thin compressor or engine manifolds or so-called thin shell type muffler elements, which can efficiently utilize the limited space of hermetically sealed compressors or small engine compartments, has been developed by the authors, as long as the thickness of the cavities is substantially small compared to the shortest wavelength of interest. However, to the authors' knowledge, a Helmholtz resonator attached to a rectangular thin muffler element, which is similar to a refrigeration compressor muffler, has not been analyzed.

Detailed diesel particulates morphology, nanostructures, fractal geometry, and nitrogen oxides (NOx) emissions were analyzed for five different test fuels in a 1.7-L, common-rail direct-injection diesel engine. The accurately formulated fuels permit the effects of sulfur, paraffins, aromatics, and naphthene concentrations to be determined. A novel thermophoretic sampling technique was used to collect particulates immediately after the exhaust valves. The morphology and nanostructures of particulate samples were examined, imaged with a high-resolution transmission electron microscope (HRTEM), and quantitatively analyzed with customized digital image processing/data acquisition systems. The results show that the particle sizes and the total mass of particulate matter (PM) emissions correlate most strongly with the fuels' aromatics and sulfur content.

The firing frequency components of the dynamic diesel particulate filter pressure signals carry significant information about the particulate load. Specifically, the normalized magnitude and relative phase of the firing frequency components exhibit clear dependence on the particulate load in a filter. Further, the test-to-test variation and back-to-back repeatability in this work was better for the dynamic pressure signal features than for the mean value pressure drop. This work provides a promising extension or alternative to the mean value pressure drop correlation to particulate load through Darcy's Law. The results may be particularly useful for filter monitoring and control.

A fast time-scale 1-D dynamic diesel particulate filter model capable of resolving the pressure pulsations due to individual cylinder firing events is presented. The purpose of this model is to investigate changes in the firing frequency component of the pulsating exhaust flow at different particulate loadings. Experimental validation data and simulation results clearly show that the magnitude and phase of the firing frequency components are directly correlated to the mass of particulate stored in a diesel particulate filter. This dynamic pressure signal information may prove particularly useful for monitoring particulate load during vehicle operation.

This paper summarizes the investigative work done to evaluate the effects of diesel substrate mounting materials on substrate surface temperatures and external shell surface temperatures. For the work completed, a test set-up and protocol was established, test results were obtained for different materials, a representative thermal model was developed, and the experimental test results were compared to the thermal model results. A stationary diesel engine incorporating secondary fuel injection for active regeneration was employed. The base test exhaust emission control systems consisted of a DOC + uncatalyzed DPF configuration. An appropriate data acquisition and thermocouple map was developed to monitor the exhaust system temperature conditions. The test cycle employed consisted of a soot loading segment, a standard filter regeneration segment, and a transient regeneration segment.

Gas-to-Liquids (GTL) is a liquid diesel fuel produced from natural gas, which may have certain attributes different from conventional ultra low sulfur diesel (ULSD). In this investigation, GTL, ULSD, and their blends of 20% and 50% GTL in ULSD were tested in an older Mercedes C Class (MY1999, Euro 2) and a newer Opel Astra (MY2006, Euro 4) diesel vehicle to evaluate the performance in terms of fuel consumption and emissions. Each vehicle was pre-conditioned on-road with one tank full of test fuel before actual testing in a chassis dynamometer facility. Both vehicles were calibrated for European emission standards and operation, and they were not re-calibrated for the fuel tests at Argonne National Laboratory (ANL). In the two-vehicle EPA FTP-75, US06, and Highway drive-cycle tests, the emissions of carbon dioxide on a per-mile basis (g/mi) from all GTL-containing fuels were significantly lower than those from the ULSD.

As the use of diesel engines increases in the transportation industry and emission regulations tighten, the implementation of diesel particulate filter systems has expanded. There are many challenges associated with the design and development of these systems. Some of the key robustness parameters include regeneration, efficiency, fuel penalty, engine performance, and durability. One component of durability in a diesel particulate filter (DPF) system is the filter's ability to resist ring-off-cracking (ROC). ROC is described as a crack caused primarily by thermal gradients, differentials, and the resulting stresses within the DPF that exceed its internal strength. These cracks usually run perpendicular to the substrate flow axis and typically result in the breaking of the substrate into separate halves.

In an effort of providing better understanding of regeneration mechanisms of diesel particulate matter (PM), this experimental investigation focused on evaluating the amount of heat release generated during the thermal reaction of diesel PM and the concentrations of soluble organic compounds (SOCs) dissolved in PM emissions. Differences in oxidation behaviors were observed for two different diesel PM samples: a SOC-containing PM sample and a dry soot sample with no SOCs. Both samples were collected from a cordierite particulate filter membrane in a thermal reactor connected to the exhaust pipe of a light-duty diesel engine. A differential scanning calorimeter (DSC) and a thermogravimetric analyzer (TGA) were used to measure the amount of heat release during oxidation, along with subsequent oxidation rates and the concentrations of SOCs dissolved in particulate samples, respectively.

The limited spatial area in conventional diesel particulate filter (DPF) systems requires frequent regenerations to remove collected particulate matter (PM) emissions, consequently resulting in higher energy consumption and potential material failure. Due to the complex geometry and difficulty in access to the internal structure of diesel particulate filters, in addition, many important characteristics in filtration processes remain unknown. In this work, therefore, the geometry of DPF membrane channels was modified basically to increase the filtration areas, and their filtration characteristics were evaluated in terms of pressure drop across the DPF membranes, effects of soot loading on pressure drop, and qualitative soot mass distribution in the membrane channels. In this evaluation, an analytical model was developed for pressure drop, which allowed a parametric study with those modified membranes.

At the current stage of engine technology, diesel engines typically require diesel particulate filter (DPF) systems to meet recent particulate emissions standards. To assure the performance and reliability of DPF systems, profound understanding of filtration and regeneration mechanisms is required. Among extensive efforts for developing advanced DPF systems, the development of effective thermal management strategies, which control the thermal runaway taking place in oxidation of an excess amount of soot deposit in DPF, is quite challenging. This difficulty stems mainly from lack of sufficient knowledge and understanding about DPF regeneration mechanisms, which need detailed information about oxidation of diesel particulate matter (PM). Therefore, this work carried out a series of oxidation experiments of diesel particulates collected from a DPF on a diesel engine, and evaluated the oxidation rates of the samples using a thermo-gravimetric analyzer (TGA).

This paper discusses trends in environmental regulations to achieve tighter emission standards for vehicles, which is reflected in the design and components of catalytic converters. Catalytic converters are being located closer to the engine to achieve faster catalyst activity and quicker emission reduction. The ceramic monoliths are also changing to provide a higher number of cells per area resulting in reduced mass, wall thickness and mechanical strength. These designs are demanding new mounting materials that can provide broader temperature capability, while maintaining the ability to hold the ceramic monolith inside the can without damage to the ceramic monolith. New reduced vermiculite intumescent materials, non-intumescent materials and combinations of intumescent and non-intumescent materials are discussed to address the compatibility with the new monoliths and broader operating temperatures.

Experimental modal analysis (EMA) provides many parameters that are required in numerical modeling of dynamic and vibratory behavior of structures. This paper discusses EMA on an exhaust system of an off-road car. The exhaust structure is tested under three boundary conditions: free-free, supported with two elastomeric mounts, and mounted to the car. The free-free modal parameters are compared to finite element results. The two-mount tests are done with the mounts fixed to a rigid and heavy frame. The rigidity of the frame is verified experimentally. The on-car test is done with realistic boundary conditions, where the exhaust structure is fixed to the engine manifold as well as the two elastomeric mounts. The two-mount and the on-car tests result in highly complex mode shapes.

The physical and morphological properties of the particulate matter emitted from a 1.7-liter light-duty diesel engine were characterized by observing its evolution in size and fractal geometry along the exhaust system. A common-rail direct-injection diesel engine, the exhaust system of which was equipped with a turbocharger, EGR, and two oxidation catalysts, was powered with a California low-sulfur diesel fuel at various engine-operating conditions. A unique thermophoretic sampling system, a high-resolution transmission electron microscope (TEM), and customized image processing/data acquisition systems were key instruments that were used for the collection of particulate matter, subsequent imaging of particle morphology, and detailed analysis of particle dimensions and fractal geometry, respectively. The measurements were carried out at four different positions along the exhaust pipe.

Dual-fuel combustion using port-injection of low reactivity fuel combined with direct injection of a higher reactivity fuel, otherwise known as Reactivity Controlled Compression Ignition (RCCI), has been shown as a method to achieve high efficiency combustion with moderate peak pressure rise rates, low engine-out soot and NOx emissions. A key requirement for extending to high-load operation is reduce the reactivity of the premixed charge prior to the diesel injection. One way to accomplish this is to use a very low reactivity fuel such as natural gas. In this work, experimental testing was conducted on a 13L multi-cylinder heavy-duty diesel engine modified to operate using RCCI combustion with port injection of natural gas and direct injection of diesel fuel. Natural gas/diesel RCCI engine operation is compared over the EPA Heavy-Duty 13 mode supplemental emissions test with and without EGR.

Diesel engine cylinder deactivation (CDA) can be used to reduce petroleum consumption and greenhouse gas (GHG) emissions of the global freight transportation system. Heavy duty trucks require complex exhaust aftertreatment (A/T) in order to meet stringent emission regulations. Efficient reduction of engine-out emissions require a certain A/T system temperature range, which is achieved by thermal management via control of engine exhaust flow and temperature. Fuel efficient thermal management is a significant challenge, particularly during cold start, extended idle, urban driving, and vehicle operation in cold ambient conditions. CDA results in airflow reductions at low loads. Airflow reductions generally result in higher exhaust gas temperatures and lower exhaust flow rates, which are beneficial for maintaining already elevated component temperatures. Airflow reductions also reduce pumping work, which improves fuel efficiency.

A three-dimensional (3-D) computational fluid dynamics (CFD) code has been developed to predict flow dynamics and pressure drop characteristics in geometry-modified filters in which the normalized distance of the outlet channel plugs from the inlet has been varied at 0.25, 0.50, and 0.75. In clean filter simulations, the pressure drop in geometry-modified filters showed higher values than for conventional filters because of the significant change in the pressure field formed inside the channel that determines the amount of flow entering the modified channel. This flow through the modified channel depends on plug position initially but has a maximum limit when pressure difference and geometrical change are compromised. For soot loading simulations, a Lagrangian multiphase flow model was used to interpret the hydrodynamics of particle-laden flow with realistic inputs.

The latest US emission regulations require dramatic reductions in Nitrogen Oxide (NOx) emissions from vehicular diesel engines. Selective Catalytic Reduction (SCR) is the current technology that achieves NOx reductions of up to 90%. It is typically mounted downstream of the existing after-treatment system, i.e., after the Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF). Accurate prediction of input NO₂:NO ratio is useful for control of SCR urea injection to reduce NOx output and NH₃ slippage downstream of the SCR catalyst. Most oxidation of NO to NO₂ occurs in the DOC since its main function is to oxidize emission constituents. The DOC thus determines the NO₂:NO ratio as feedgas to the SCR catalyst. The prediction of NO₂:NO ratio varies as the catalyst in the DOC ages or deteriorates due to poisoning. Thus, the DOC prediction model has to take into account the correlation of DOC conversion effectiveness and the aging of the catalyst.