I N T E R N A T I O N A L

The Engineering SocietyFor Advancing Mobility

Land Sea Air and Space

Backpressure Optimized MetalSupported Close Coupled PE Catalyst -

First Application on a Maserati Powertrain

Corrado Iotti, Vincenzo Rossi, Luca PoggioFerrari S.p.A.

Mathias HolzingerArvinMeritor

Lorenzo Pace, Manuel PrestiEMITEC GmbH

2005-01-1105SAE TECHNICALPAPER SERIES

SAE World Congress

Detroit, Michigan

April 11 - 14, 2005

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2005 0 05

Bac pressure pti i ed C se C up ed PE Cata yst First

App icati a aserati P wertrai

C rrad I tti Vi ce R ssi uca P ggiFerrari S p A

athias H i gerArvi erit r

re Pace a ue Presti E ITEC G bH

ABSTRACT

Future stri ge t e issi i its b th i the Eur peaC u ity a d USA require c ti u us y i creasedc versi efficie cy f exhaust after treat e tsyste s

Besides the bvi us targets f fastest ight ffperf r a ce vera c versi efficie cy a d durabi itycata ytic c verters f r axi u utput e gi es require high y pti i ed f w pr perties as we i rder tcreate i i u exhaust bac pressure f r w fuec su pti

This w r dea s with the desig deve p e t a d seriai tr ducti f a c se c up ed ai cata yst systeusi g the i vative tech gy f Perf rated F i s (PE)

By ea s f PE tech gy cha e t cha e gas ixi g withi the eta substrate c u d be achieved

eadi g t dra atica y reduced bac pressure va uesc pared with the c ve ti a desig

Due t the high y i pr ved f w pr perties f the adva ced eta substrate a c pact c verter c u d be desig ed ta i g i t acc u t the de a di g pac agi gc strai ts i a der V8 e gi e c part e t

The prese t paper c sists f u erica si u ati sf w be ch a d e gi e test be ch easure e ts carried

ut t assess e issi perf r a ce bac pressureadva tage a d e gi e p wer utput i crease f a c se

c up ed si g e bric syste c p ia t with EV II a dEU4 e issi i its

I TR DUCTI

Due t the re stri ge t e issi egis ati i its it wi be ecessary i the ear future t use cata yticsupp rt with either high ce de sity r with a cascade architecture It is we pr ved that the high ce de sitysupp rts up t 600cpsi have i pr ved the c d start behavi r a d the efficie cy duri g war ed up c diti

2 3 4 5

It ay be p ssib e t reduce the t ta bac pressure f a high ce de sity supp rt usi g u tra thi f i s a d v u ereducti h wever ai tai i g the sa e HC a d Cc versi efficie cy wi require u if r f w distributiwhich pac agi g a d bac pressure c strai ts ay ta w

the ther ha d a ther strategy t c p y with future e issi egis ati is t use a cascade syste6 7 a th ugh i s e app icati s pac agi gc strai ts d t a w its app icati

e a ter ative s uti that i pr ves bac pressureperf r a ce f the syste with ut a y space c strai tis represe ted by the Perf rated F i s tech gy

THE PERF RATED F I S TECH GY

Pri cip e

Perf rated F i s (PE) tech gy has bee a readysuccessfu y i tr duced i ass pr ducti i differe tapp icati s a d th r ugh y discussed i previ us w r s8 9 F r sa e f c arity th ugh the pri cipa

characteristic are re stated i this paper as we

The PE Tech gy (Fig ) c sists f perf rati g b thf at a d c rrugated f i s creati g a radia f w betweead ace t cha e s The ss f GSA is verc pe satedby the creati f Turbu e t i e f ws

The deve p e t f eta f i s with perf rati has pr isi g adva tages

homogeneous distribution of flow and pollutant concentrations

compensation of lambda cylinder-to-cylinder variations

reduction of heat capacity

backpressure reduction

Fig Perf rated f at a d c rrugated f i

Tech gy

I rder t i vestigate the bac pressure perf r a ce fthe PE Supp rt tw differe t test with tw differe tsupp rts have bee carried ut

The first test is a c paris betwee eta ic a dcera ic supp rt u c ated b th 0x74 5 400cpsiwith 65 f i a d 4 i s wa respective y B th a eve

bee tested the atter btai ed by a diaphrag that p ugs 50% f the i et surface

easure e t were c ducted by Ferrari aserati i a stati ary f w be ch with 20 C te perature f w

Fig 2 i ustrates the resu ts f the first easure e twith eve f w distributi

0

5

10

15

20

25

0,25 0,3 0,35 0,4 0,45 0,5

Mass Flow Rate [Kg/s]

Backp

ressu

re [

mb

ar]

Ceramic

PE Metalit

Fig 2 Resu t f the bac pressure easure e t with eve f wdistributi

The bac pressure f the tw supp rt are quite si i arwith a ight adva tage f the eta it at high ass f wrate

Fig 3 i ustrates the resu ts f the sec d easure e twith u eve f w distributi

The resu ts f this easure e t sh ws a c siste tadva tage f the PE eta it the bac pressure is 7%

wer at a ass f w rate f 0 350 g s

0

5

10

15

20

25

30

35

40

0,15 0,2 0,25 0,3 0,35 0,4

Mass Flow rate [Kg/s]

Ba

ck

pre

ss

ure

[m

ba

r] Ceramic

PE Metalit

Fig 3 Resu t f the bac pressure easure e t with u evef w distributi

Bac pressure Perf r a ce f The PE

f w distributi a d a high y u eve f w distributi have

After these first pr isi g resu ts it was decided ta e further c d f w easure e ts with the

pr ducti i te ded e iptica shaped c verter which pti a y fits the space c strai t f the aserati V8

u derh d c part e t

The sec d array f tests have bee carried ut at the E itec R&D Ce ter i Eise ach with 00 C f wte perature u c ated c verters a cera ic bric

52 4 0 6x 39 9 400 cpsi 4 i s a d a eta icsubstrate 67 02x 20 500 cpsi PE 50

These easure e ts were perf r ed with eve a du eve f w (the atter btai ed with a diaphrag which p ugs 50% f the i et cr ss secti )

The first easure e t (Fig 4) with eve f w distributish ws a syste atic adva tage f the PE eta it The PE structure a d the s ight y greater i et surface area

verc pe sate the higher cpsi f the eta it

0

2

4

6

8

10

12

100 150 200 250 300 250 400 450

Volumetric Flow Rate [Nm³/h]

Ba

ck

pre

ss

ure

[m

ba

r] Ceramic

PE Metalit

Fig 4 Bac pressure easure e t e iptica supp rts with eve f w distributi

Fig 5 sh ws the resu t f the easure e t carried utwith u eve f w distributi The adva tage f the PE

eta it is here c ear at 450 h the bac pressure fPE eta it is 52% f the bac pressure f the Cera icsupp rt

0

5

10

15

20

25

30

35

40

100 150 200 250 300 250 400 450

Volumetric Flow Rate [Nm³/h]

Ba

ck

pre

ss

ure

[m

ba

r] Ceramic

PE Metalit

Fig 5 Bac pressure easure e t e iptica supp rt with u eve f w distributi

The ai reas f r the great adva tage ibac pressure re evide t with u eve f wdistributi is due t the abi ity t s th ut the radiapressure gradie ts a d t achieve equa i ed ve citydistributi I rder t better u dersta d the pr perties

f e iptica PE eta it a f w distributi easure e twas carried ut c pari g a sta dard eta it with a PE substrate The u tu ed exhaust a if d versi Step

deve ped by Arvi erit r has bee used f r this easure e t

Fig 6 Ve city distributi f r a sta dard ( eft) a d PE (right) eta it

It is c ear fr Fig 6 that the ve city pea s i the PE eta it are uch wer tha i sta dard eta it This

resu t is a i pr ve e t f the U if r ity I dex 0fr 0 90 (sta dard) t 0 93 (PE)

Moreover the normalized velocity gradient (x

w

m&

1) has

been calculated for the two supports. (Fig. 7)

Fig 7 Ve city gradie t f r a sta dard ( eft) a d PE (right) eta it

The sta dard supp rt has a axi a r a i edgradie t va ue f 7 0 g whi e the PE substrate sh ws a axi a va ue f y 2 9 g This is c sidered t be a sig ifica t i pr ve e t as werpressure gradie ts reduce echa ica ads the substrate

F w ixi g Effects

The f w ixi g pr perty f the PE eta it a s has a p sitive i f ue ce cata ytic efficie cy I a previ uspaper 9 it was de strated that the HC C a d x

a gas i e turb charged e gi e ca be reduced by 30% 40% a d 60% respective y (Fig 8) The c verters

tested were 85x90 400cpsi 50 a d 40 PE respective y

0

100

THC CO NOx

% o

f L

EV

Lim

it

Standard Metalit PE Metalit

Fig 8 Efficie cy f a sta dard a d PE eta it a 8 Cy i der4 2 Gas i e E gi e FTP 75 Cyc e

C sideri g that the i pr ve e t f cata ytic efficie cyi ab ve e ti ed app icati is t y re ated t the ad pti f PE tech gy but a s ther desig

easures such as a t e air gap i su ati thi er f i setc additi a app icati pr gra s have bee carried

ut t i vestigate the i f ue ce f PE Structure cata ytic efficie cy

T this ai a c paris betwee tw eta it98 4x 0 800cpsi 40 with a d with ut PE

structure has bee carried ut a pr ducti 2 4Cy i der e gi e

0

0,02

0,04

0,06

0,08

0,1

HC CO / 10 NOx

HC

, C

O/1

0, N

Ox [

g/k

m]

Standard Metalit PE Metalit

Fig 9 Efficie cy f a sta dard a d PE eta it a 2e gi e

Whi e C e issi eve re ai s u i f ue ced ( 8%)HC a d x e issi s are reduced by 9% a d 23% respective y (Fig 9)

The easure e t were carried ut a r er test be chby E itec Research Ce ter i Eise ach

The sig ifica t bac pressure adva tages f PE a gwith expected e issi i pr ve e t ffered by the c se c up ed cat desig ead t the fi a desig fthe exhaust syste f r a ew V8 aserati app icati

TECH ICA E GI EERI G FR DESIG T

VEHIC E APP ICATI

The first cha e gi g issue was t desig a ew exhaust a if d that ight a w a re ative y c sed c up ed

p siti f r the cat ta i g i t c siderati the space c strai t f the aserati V8 E gi e

Fig 0 sh ws the first 3 D desig f the c se c up edPE cat The ew desig c sists i a 4 iexhaust a if d with PE cat appr xi ate y 500

fr cy i der head

Fig 0 First 3 D desig f the PE eta it cat

C sideri g that the pr ducti syste c sists f a cascade syste with the first bric c ser t the e gi etha the PE cat it was ecessary t a e s esi u ati regardi g the war up perf r a ces f such a syste The PE structure is i this case aadva tage bei g the ther a ass f a PE ith

ear y 38% wer tha a sta dard supp rt

200

300

400

500

600

700

800

900

0 20 40 60 80 100 120

Time [sec]

Ga

s T

em

pe

ratu

re [

K]

Production system

PE Monolith

Fig War up si u ati Pr ducti syste (cascade) vsPE eta it cat 200 further d w strea

Fig sh ws the War up si u ati f the pr ductisyste c pared t the PE eta it It ca be bservedthat the te perature i fr t f the PE cat is c parab e t the te perature i fr t f the pr ducti

syste This ea s that the desig dificati s f the exhaust syste ge etry d es t affect the te perature pr fi es i fr t f the supp rt I this case it was expected at east disadva tage f PE catc pari g t the cascade syste duri g ight ff phaseI fact a adva tage was bserved with the PE eta itduri g the bag f the FTP 75 Cyc e (Fig 5)

As a sec d step f this w r a CFD si u ati was carried ut i rder t eva uate the i pact f the 4 i

a if d fr t face f w distributi Fig 2 sh ws the c putati a d ai f r the CFD si u ati

Fig 2 C putati a d ai f r the CFD si u ati f PE eta it cat

The resu ts b th i ter s f U if r ity I dex 0 a dradia pressure gradie t were pr isi g but sti tsatisfact ry a further i pr ve e t was ecessary

Fig 3 Si u ated ve city fie d f r PE eta it cat

It ca be a s bserved h w the si u ati (cy i der 6Fig 3) a d the easure e t (Fig 6) basica y give the sa e resu ts Further re it is appare t h w the ve cityfie d is c ce trated (Cy i der 5 7 a d 8) i a peripherapart f the atrix which is a p te tia issue f r durabi ity

C sideri g these first resu t pr isi g it was decided t test the syste e gi e be ch t better eva uatethe rea adva tages i ter s f p wer a d t rque utputa d e issi efficie cy

FIRST EVA UATI ASERATI E GI E

axi u P wer a d T rque

The ew V8 aserati e gi e is a be ch ar t y iter s f axi u p wer utput but a s i ter fdriveabi ity As e ti ed e f the targets f the prese t w r was t i crease b th the axi u p wera d the ediu rp ra ge t rque

A step syste was tested a test rig with dificati e gi e a age e t i rder t c ear y

see the practica adva tages f this s uti

Previ us y the tw syste s b th c ated were tested a f w be ch The cat syste sh ws a adva tage

f ear y 34% t ta syste bac pressure

A adva tage i ter f axi u p wer f ab ut 2% was easured A s the adva tage i ter s f t rquewas c ear at ediu rp ra ge As a exa p e aadva tage f 5% was easured at 3500rp

C versi Efficie cy

As a further step the e issi efficie cy was tested

eta it with a appr priate c ati g tech gy Whec ati g PE f i substrate tw differe ces frc ve ti a eta ic substrate have t be c sidered

p rti s f issi g ce wa s a d sec d y the cha e sare t c ti u us as they have pe i gs t their

eighb uri g ce s

Theref re PE substrates require cha ges t be ade tthe three way cata yst f r u ati a d it’s c ati gpara eters t give a pti i ed pr duct After uchdeve p e t w r a ew f r u ati specifica y f r PEsubstrate was deve ped by h s atthey that gives

w bac pressure a d very high cata ytic activity after high te perature agei g This f r u ati was used duri g this study

B th syste s were tested i fresh c diti A further i vestigati regardi g agi g is i pr gress

B th syste s were c ated by h s atthey the PE

First y PE substrate has reduced surface area due t

0%

20%

40%

60%

80%

100%

HC

HC +

NOx

CO

NOxR

ela

tiv

e e

mm

iss

ion

[-]

Production system PE Mealit

Fig 4 Re ative e issi f pr ducti syste vs PE eta it

It ca be easi y bserved i Fig 4 that there is a 30% i pr ve e t HC X a d c seque t y HC

X It is re ar ab e the ther ha d the ticeab ei pr ve e t C e issi eve 70%

It sh u d be a s stressed that the t ta cata yst v u ehas bee reduced by ab ut 5%

With regard t ight ff perf r a ce it ca be ticedfr the data isted i Fig 5 that the PE eta itsyste sh ws a re ar ab e adva tage

0%

20%

40%

60%

80%

100%

HC CO NOx

Re

lati

ve

em

mis

sio

n [

-]

Production system PE Mealit

Fig 5 Re ative e issi duri g Bag f pr ducti systevs PE eta it

It sh u d be ted that b th p wer a d t rque as weas e issi efficie cy i pr ve e t are btai ed with uta y e gi e a age e t dificati a d with a utu ed exhaust a if d The pti i ati f the exhaust

a if d is exp ai ed i the ext chapter

DESIG I PR VE E T

CFD pti i ati f ca i g

I rder t pti i e the exhaust a if d a CFD para etric a a ysis was carried ut The g a f this

pti i ati was t reach a U if r ity I dex f r acy i der f r ugh y 0 85 a d a pressure gradie t wertha 0 bar

The g a was reached usi g a cust swaged i et c ei rder t better distribute the f w a d t detach the

ai strea fr the periphera e

Fig 6 sh ws the CFD c putati a d ai used tsi u ate the step 8 f the pti i ati pr cess

Fig 6 C putati a d ai f r the CFD si u ati fpti i ed PE eta it cat

Fig 7 sh ws the ve city fie d f the pti i ed exhaust a if d

Fig 7 Si u ated ve city fie d f r pti i ed PE eta itcat

The f w is uch re u if r c pared t the step a d is a s re ce tered That has a p sitive i f ue ce

ith durabi ity

T better predict the p ssib e issue durabi ity a easure e t ca paig was carried ut

Te perature Te perature Tra sie t a d

Vibrati easure e t

E itec has deve ped duri g the past years a tech ique that easures axi a te perature axi ap sitive a d egative te perature tra sie t a d vibratieve

It is very i p rta t t carry ut such easure e t i the ear y stage f the pr ect i rder t pti i e substrate desig t av id a y ver e gi eeri g

Te perature easure e t are carried ut usi g thither c up es (i this case Type 0 75 ) i serted ithe substrate with ut da agi g the substrate itse f The ther c up es ust be very thi i rder t have a wther a ass Because the sa p i g freque cy is 0Hit is p ssib e t easure the very sharp te peraturegradie ts that usua y ta e p ace i the supp rt

The test c sist f a W T acce erati starti g fr the west p ssib e stab e e gi e speed i first gear up t

6th gear rp i iter

The easured te perature eve (fig 8) d es texceed the axi u rec e ded va ue whi e the te perature gradie ts are high due t wa fi effect

te that duri g this easure e t tu i g f t ra age e t such as thr tt e va ve pe c se strategy

was perf r ed

Fig 8 Te perature a d Te perature tra sie t duri g test

Vibrati easure e t are carried ut with pie e ectricse s rs fixed t the c verter a te by ea s f water c ed adapters The ra ge f easured freque cy is up t 4 H

The test c sist f a 4th gear W T acce erati fr the west p ssib e stab e e gi e speed up t the rp

i iter I this case the test durati was ab ut 22sec

Fig 9 sh ws the Ca pbe diagra easured duri gthe testi g acr ss the axia directi The data sh ws aabse ce f res a ce

Fig 9 Ca pbe diagra

Fig 20 sh ws the R S A p itude diagra p tted versus the Freque cy The wer freque cy high A p itudeva ues are t usua y da ger us f r the ith bei gthe atrix res a ce freque cy usua y uch higher

0 500 1000 1500 2000 2500 3000 3500 4000

0

10

20

30

40

50

60

XkatS

YkatS

ZkatS

RM

S-A

mplit

ude (

m/s

²)/H

z

Frequenz [Hz]Frequency [Hz]

0 500 1000 1500 2000 2500 3000 3500 4000

0

10

20

30

40

50

60

XkatS

YkatS

ZkatS

RM

S-A

mplit

ude (

m/s

²)/H

z

Frequenz [Hz]Frequency [Hz]

Fig 20 R S A p itude vs Freque cy

It ca be asserted that vibrati eve is wide u der the rec e ded i it f r such ith app icati

C C USI

A ew exhaust gas syste has bee deve ped i rdert eet the p wer a d t rque g a f aserati ta i gi t c siderati the space c strai t f the V8 e gi e

F r this ai the ew E itec PE eta it has beei te sive y tested b th f w a d e gi e be ch i

rder t a e evide t the bac pressure adva tages fthis i vative ith

I the ear y phases f the pr ect ight ff a d CFD si u ati were carried ut t better u dersta d the effects f cata yst cati a d i et surface f wdistributi f the PE eta it

I rder t e ha ce the f w pr perties bac pressurecharacteristic a d the expected e issi p te tia f PE

eta it pti i ed c ati g tech gies have beedeve ped by h s atthey

The e issi easure e t c fir s the high efficie cyf the PE eta it b th i c d start phase as we as i

war c diti eve if the t ta cata yst v u e has bee reduced f ab ut 5%

re ver Te perature Te perature Tra sie t a dVibrati easure e t were c ducted t sh w the p ssib e prese ce f te perature pea high te perature tra sie t a d ith res a ce

The p wer utput adva tage f 2% a d the 5% t rqueadva tage at the ediu rp ra ge are the ey resu ts

f this w r

AC W EDGE E TS

We are gratefu t h s atthey f r the c perativew r i deve pi g this adva ced ew s uti

REFERE CES

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0929 P. Marsh, F. Acke, Volvo/ R. Konieczny, R. Brück, P. Hirth, Emitec GmbH

[2] “Product Design and Development of Ultra Thin Wall Ceramic Catalytic Substrate”, SAE – Paper 2002-01-0350 Yoichi Aoki, Yukio Miyairi, Yukihito Ichikawa, Fumio Abe NGK Insulaters Ltd

[3] “Design Criteria for Metallic Substrates for Catalytic Converters“, SAE – Paper 950789 R. Brück, R. Diewald, P. Hirth, F.-W. Kaiser, Emitec GmbH

[4] “Design Criteria for Metallic Substrates for Future Catalyst Applications, Part III“, SAE-Paper 971027 A. Bergmann, R. Brück, C. Kruse, Emitec GmbH

[5] “Close-Coupled Catalytic Converters for Compliance with LEV/ULEV and EGIII Legislation – Influence of Support Material, Cell Density and Mass on Emission Results”, SAE – Paper 960261, B. Pfalzgraf, M. Rieger, G. Ottowitz, AUDI AG

[6] “Das BMW SULEV ( PZEV ) Konzept - Emissionsreduzierung ohne Kompromisse, Wien Motorensymposium 2002 J. Liebl, R. Hofmann, Th. Melcher, BMW AG

[7] “The development of BMW Catalyst Concepts for LEV/ULEV and EUIII/IV Legislations 6 Cylinder Engine with Close Coupled Main Catalyst”, SAE – Paper 980418 E. Otto, F. Albrecht, J. Liebl, BMW AG

[8] “Next generation catalysts are turbulent: development of support and coating”, SAE-Paper 2004-01-1488, M. Bollig, J. Liebl, R. Zimmer BMW Group, M. Kraum, O. Seel, S. Siemund, Engelhard Technologies GmbH, R. Brück, J. Diringer, W. Maus, Emitec GmbH

[9] „Innovatives Katalysatorsystem für den Audi RS6, 8 Zyl, 4,2ltr, 331 KW mit LEV Zertifizierung“, Wiener Motoren Symposium, 29-30.April 2004,. M. Ganz, S. Hackmayer, quattro GmbH, C. Kruse, A. Reck, Emitec GmbH

[10] „Optimisation of Catalytic Converter Gas Flow Distributionby CFD Prediction“,SAE – Paper 930780, H. Weltens, H. Bressler, F. Terres, H. Neumaier, D. Rammoser, Heinrich Gillet GmbH & Co. KG