Corrosion Behavior of Aluminized Stainless Steels and Stainless Steels in Simulated Muffler Condensate-Corrosion Conditions

Increasing service-life requirements for automobile and truck exhaust system components and the problem of potentially severe corrosivity of cold-end exhaust system condensate have greatly increased interest in the use of advanced construction materials for cold-end components. Studies on dynamometer test systems have shown that condensate can exhibit relatively high soluble salt content and variable pH ranging from mildly alkaline to appreciably acidic depending mainly upon driving conditions, catalytic converter mode of operation, air/fuel ratio and fuel chemistry. In these circumstances, there is considerable interest in determining the advantages afforded by aluminized stainless steel and various grades of stainless steel as construction materials. The primary goal of the present study was to achieve realistic relative materials behavior in laboratory testing by simulating realistic chemical/physical muffler environmental conditions.