Development of Novel Composite Coatings for Emissions Catalyst Performance Improvement

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Thin films of composite ceramic coating can be applied to standard engine materials to affect the heat transfer properties and therefore internal and external surface temperatures. The extent of these changes, or heat transfer characteristics, can be changed by adapting the coating formulation, which is a technology Fireball, the industrial partner, has been studying. New regulations for diesel engines require new catalytic converter technology to be applied. These catalysts require exhaust gas temperatures typically higher than those encountered in passenger diesel vehicles under normal driving conditions. In order to maintain catalyst efficiencies, the exhaust gas can be heated by running the engine hotter, but obviously at a fuel penalty cost. Thin film coatings could be a solution to minimize or eliminate this fuel cost, by decreasing the heat transfer through the pipe to the environment. Such coatings would need to be optimized for heat transfer minimization, but also be able to maintain its integrity in the corrosive exhaust gas environment. The integrity needs to be studied and findings used to optimize the coating formulation. Furthermore, the decrease in heat transfer needs to be quantified, with the increase in exhaust gas temperature measured and the improvement in catalyst efficiency as a function of that temperature increase also measured in order to understand the extent of the effect on emissions reduction performance and decreased fuel penalties. The objectives therefore include formulation testing under exhaust gas conditions, measuring exhaust gas temperatures as a function of coating formulation, and extent of catalyst efficiency improvement and fuel penalty decrease associated with the coating application. If proven, this technology can be applied on exhaust pipes for diesel engine applications, representing a very significant increase in the industry partner's customer base and employment potential.