Abstract
Diffuser plates in exhaust system manifolds are designed to provide uniform flow pattern within the manifold for maximum utilization of the catalytic converter substrate during high-temperature applications. In this paper, failure analysis of a diffuser which survived only 20% duration of a manifold crack test and various design optimization studies of the diffuser plate using computer-aided engineering (CAE) analyses are presented. During the manifold crack test, the failure occurred at the inner and outer periphery of the diffuser. Metallurgical failure analysis coupled with CAE thermal fatigue analysis of the component concluded that thermal fatigue was the root cause of the failure. The new recommended robust design showed considerable improvement in the thermal durability of the diffuser plate assembly.
Similar content being viewed by others
References
L. Meda, H. Lawrenz, M. Romzek, D. Gilmer, “Structural durability evaluation of exhaust system components”, SAE 2007-01-0467
ASTM E 1086-08 “Standard test method for optical emission vacuum spectro analysis of stainless steel by the point to plane excitation technique, 2008”
EN 10088-1:2005(E) “Stainless steels – Part 1: List of stainless steels”
ASTM E3-11 “Standard guide for preparation of metallographic specimens”
ASTM E384-11E1 “Standard test method for knop and Vickers hardness of materials”
S. Chowdhury, S. Taguchi, “Robust Optimization: World’s Best Practices for Developing Winning Vehicles”, Print ISBN: 9781119212126
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Joshi, B., Shih, HR. & Rose, B. Failure Analysis and Robust Optimization of an Exhaust Manifold Diffuser Plate. J Fail. Anal. and Preven. 18, 486–495 (2018). https://doi.org/10.1007/s11668-018-0459-8
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11668-018-0459-8