Implementation of new materials or processes in the automotive industry are typically driven by the desire to improving fuel economy and customer satisfaction while reducing cost. Microstructural characterization is typically employed to assist in failure analysis of proto-type components or to evaluate the effect of process changes on microstructure. The types of materials under investigation include steels, aluminum, magnesium and polymers used primarily in body panel applications, steels and cast aluminum for powertrain components, and ceramics utilized in exhaust gas catalysts and various sensors. Three examples of materials characterization are presented below.Aging studies of three-way exhaust gas catalysts. Automotive three-way catalysts (TWCs) are most often comprised of a cordierite monolith coated with a washcoat containing Al 2 O 3 , CeO 2 and ZrO 2 which is impregnated with finely dispersed noble metal particles. Thermal aging and chemical poisoning are two of the primary deactivation mechanisms in TWCs. Post-mortem studies on aged catalysts can assist in understanding these failure mechanisms. Figure 1 shows WDS elemental maps of a cross section of a catalyst that was vehicle aged for 50k miles. Decomposition products of the oil additive zinc dialkyldithiophosphate (ZDDP) have deposited on the surface of the washcoat. The maps show that zinc and calcium are localized on the surface of the washcoat, while the phosphorus has migrated into the washcoat. The contamination layer on the surface blocks the washcoat pores and prevents the exhaust gas from reaching the catalytic material. TEM analysis has identified regions of AlPO 4 formed in the washcoat which can also block pores and cause a loss of surface area necessary for catalytic activity.Development of polyolefin-based nanocomposites. The development of a new generation of polyolefin-silicate clay nanocomposites requires a compatibilization process that can effectively disperse the clay throughout the polypropylene (PP) matrix in an economical way for large-scale automotive applications. Both supercritical fluid (SCF) processing and ultrasonic melt processing are currently being investigated to improve the dispersion, exfoliation and intercalation of the clay platelets. Figure 2a shows a bright-field (BF) TEM micrograph of a conventionally processed silicate-clay nanocomposite showing tightly layered tactoids. Clay platelets in materials which have been SCF processed (Figure 2b) show evidence of increased intercalation, while ultrasonication of the clay-PP mixtures during the melt state shows an increasing amount of dispersion and exfoliation (Figure 2c).Heat-treatment optimization of a cast 319 aluminum (Al) alloy. The substitution of 319 Al for cast iron in engine block and cylinder head applications results in significant weight savings. Since this alloy is heat-treatable (primary age hardening precipitate is θ-Al 2 Cu), care must be taken to insure that material properties do not degrade during the life of the vehicle. This requires a thorough k...