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Modern Diesel Engines equipped with Common-Rail Direct Injection and EGR are characterized by an increasingly high combustion efficiency. Consequently the exhaust gas temperature, especially during a cold start, is significantly reduced compared to typical values measured in previous engine generations. This leads to a potential problem with CO emission limit compliance. The present paper deals with an experimental investigation of turbulent-flow metal substrates, carried out on a vehicle roller bench using a production 1.3 Liter diesel engine equipped passenger car. The tested metal supported catalysts proved to yield extremely high conversion rates both during cold start and in warm operation phase. The improved mass transfer efficiency of the advanced metal substrates is related on one hand to the optimized coating technology and, on the other hand, to the enhanced flow performance in the single converter channels which is caused by structured metal foils.

Future stringent emission levels for NOx and PM will lead to the introduction of innovative combustion processes for diesel engines, such as premixed combustion, with the results to enhance the engine out emission of HC and CO. Therefore very efficient oxidation catalyst will be needed to face this possible issue. This paper deals with the optimization of a EU IV exhaust system by means of innovative metal supported catalyst, as for example the Pre Turbo Catalyst and the Hybrid Catalyst in combination with dedicated catalyst coatings. Moreover a base study over the use of PM-Filter Catalyst has been made, to show the efficiency of such a device with EU IV engine calibration. The second part of the paper deals with the turbulent like structured foils substrates to have an even more efficient diesel oxidation catalyst with very high volumetric efficiency.