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Increasingly stricter emission standards for gasoline and diesel engines accelerated the exhaust aftertreatment industry to develop high efficiency catalysts with innovative substrates. Engineers face thermodynamic and thermal management challenges to achieve system emission, noise and back pressure targets at minimum costs. This paper describes advanced substrate technology for exhaust after treatment systems for gasoline and diesel engines. The first part focuses on substrate technology solutions including high cell density substrates and advanced metallic substrates with structured and perforated foil material. This new substrate technology offers great potential to optimize the overall system efficiency through exhaust mixing within the catalyst at minimum back pressure. Transient temperature condition and available packaging space will have remarkable impact on system design and catalyst performance for future advanced combustion engines and hybrid vehicles.

The implementations of the Tier 2 and LEVII emission levels require fast catalyst light-off and fast closed loop control through high-speed engine management. The paper describes the development of innovative catalyst designs. During the development thermal and mechanical boundary conditions were collected and component tests conducted on test rigs to identify the emission and durability performance. The products were evaluated on a Super Imposed Test Setup (SIT) where thermal and mechanical loads are applied to the test piece simultanously and results are compared to accelerated vehicle power train endurance runs. The newly developed light-off catalyst with Perforated Foil Technology (PE) showed superior emission light-off characteristic and robustness.

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