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The diesel particulate filter (DPF) is a critical aftertreatment device for control of particulate matter (PM) emissions from a diesel engine. DPF survivability is challenged by several key factors such as: excessive thermal stress due to DPF runaway regenerations (or uncontrolled regeneration) may cause DPF substrate and washcoat failure. Catalyst poisoning elements from the diesel fuel and engine oil may cause performance degradation of the catalyzed DPF. Harsh vibration from the powertrain, as well as from the road surface, may lead to mechanical failure of the substrate and/or the matting material. Evaluations of these important validation parameters were performed.

Diesel particulate filters (DPF) made from Dow's advanced ceramic material (ACM) have already demonstrated high filtration efficiency, low pressure drop, and high temperature performance capabilities. In addition to these advantages of the ACM-DPF, it has been found to be well suited for use in combination with various catalyst coatings while maintaining it's overall advanced performance over a broad range of catalyst loadings. Our recent studies on catalyzed ACM DPF demonstrate that the unique micro structure of ACM is able to maintain significant amount of catalyst and washcoats. The characteristics of the ACM DPF pressure drop versus catalyst washcoats loading have been fully investigated. With defined coating techniques, ACM DPF can be loaded with three times the amount of washcoat than can a Silicon Carbide DPF without significantly increasing the pressure drop.