Engineering Material Selection for Automotive Exhaust Systems Using CES Software

Öz

The aim of this report is focused onreviewing the automotive exhaust system with respect to its in-service conditionsand selection of suitablematerials for exhaust manifold, downpipe silencer/ muffler box and tail pipe in an exhaust system. In doing this, the functions of each component were discussed, highlighting how they function as part of a system and CES Edupack software was employed in the material selection process. Mass, cost, high temperature (>800^oC for exhaust manifold and >400^oC for downpipe silencer/ muffler box and tail pipe) and high corrosion resistance were used as criteria for the material selection. Variety of materials including Nickel-based superalloys, stainless steel, Nickel-chromium alloys were obtained in the search result for exhaust manifold. Similarly, low alloy steels, stainless steel, grey cast iron,Nickel-based superalloys, Nickel-chromium alloys were obtained in the search result for downpipe silencer/ muffler box and tail pipe. Nickel-based superalloys and Nickel-chromium alloys possess suitable properties for this application, but were not selected due to their high densities and high cost. Low allow steels were not selected because they tends to exhibits poor corrosion resistance when exposed to salt on the road surface and condensate from the exhaust system. Grey cast iron has low tensile strength and elongation and therefore not exhibit enough toughness required to withstand the severe working conditions.However, stainless steel (Ferritic stainless steel and Austenitic stainless steel) was selected due to its considerable price, low density, excellent corrosion resistant and acceptable strength at elevated temperatures. 

Anahtar Kelimeler

• Cost,Exhaust system,Temperature,Corrosion,Mass,Material,Service life

Kaynakça

1. N. Arlt, Korrosions-und hitzebeständige Stahle in Abgassystemen. CTI Exhaust Materials Forum 21- 22.11.2007, Frankfurt, Germany, 2007.
2. D. Askeland and P. Pradeep, The Science and Engineering of Materials. Thomson Engineering, 2005.
3. M. Ashby, H. Shercliff, and D. Cebon, Materials Engineering, Science, Processing and Design. USA, Butterworth-Heinemann, 2007.
4. ATI, Stainless Steels Type 439/AL 439 HP. ATI Allegheny Ludlum Corporation Blue Sheet Technical Data, Pittsburgh, Pennsylvania, USA, 1999.
5. W. Callister, Materials Science and Engineering. New York, John Wiley & Sons, 2007.
6. D. Gaskel, Introduction to the Thermodynamics of Materials. Taylor and Francis Publishing London SW1P 1WG, 1995.
7. M. S. Chattha, J. Perry, R. L. Goss, C. R. Peters, H. S. Gandhi, Corrosion of aluminized low carbon steel exhaust system in vehicles equipped with three-way catalytic converters and development of a protective polymeric coating, Ind. Eng. Chem. Res., 29 (7), 1438-1442, 1990.
8. P. Gumpel and C. Hoffmann, Corrosion resistance of stainless steels to wet condensates in automotive exhaust systems. Proceedings of the 6th European Stainless Steel Conference, Helsinki, 2008.

9. D. Green, R. Hannink and M. Swain, Transformation Toughening of Ceramics. Boca Raton: CRC Press, 1989.
10. Y. Inoue and M. Kikuchi, Present and future trends of stainless steel for automotive exhaust system”, Nippon Steel Technical Report No. 88, 2003.
11. A. E. Ikpe, I. Owunna, P. O. Ebunilo and E. E. Ikpe, Material Selection for High Pressure (HP) Turbine Blade of Conventional Turbojet Engines. American Journal of Mechanical and Industrial Engineering 1 (1), 1-9, 2016.
12. P. Lewis, K. Reynolds and C. Gagg, Forensic Materials Engineering: Case Studies. Boca Raton: CRC Press, 2003.
13. F. Mathews and R. Rawlings, Composite Materials: Engineering and Science. . Boca Raton: CRC Press, 1999.
14. Precision Automobile, exhaust system [online] available at http://www.precisionautosales.com/exhaust.php, 2000.
15. J. Shackelford, Material Science for Engineers. Prentice Hall: Upper Saddle River, 2000.
16. K. Zimmermann, Lightweight design in exhaust systems using tailored products. 9th International CTI Forum Exhaust Systems, January 26, 2011, Stuttgart, Germany, 2011.