Application of a New Metal Catalyst Substrate Generation for Two and Three Wheelers

Affordable, efficient and durable catalytic converters for the two and three wheeler industry in developing countries like India are required to reduce vehicle emissions and to maintain them at a low level and therefore to participate in a cleaner and healthier environment. A new generation of metallic substrates with structured foils for catalytic converters has been proven capable of improving conversion behavior even with smaller catalyst size. Specially developed foil structures which transform a laminar exhaust gas flow into a turbulent one, which significantly improve exhaust gas mixing behavior in the catalyst. This publication will deal with the analysis of different metallic substrate foil structures for the catalyst conversion performance for the leading “state of the art” four stroke 150 cm³ motorcycle technology developed for the Asian market. The impact of turbulent substrate foil structures compared to standard foils tested on engine test bench in aged state will be discussed in depth. In particular, turbulent catalytic converters with longitudinal and perforated substrate foil structures, and the influence of the catalyst volume (the benefit of a 15% reduced volume) and PGM loadings (22, 40 and 55 g/ft³) on its conversion will be examined. A primary investigation carried out on the same vehicle with different catalytic converters is also reported.