Performance Advantages of Polycrystalline Alumina Fiber Non-intumescent Mat in Catalytic Converters

The purpose of this paper is to identify the distinguishing characteristics of Polycrystalline Alumina fiber as a support mat in catalytic converters and the resulting improvements for Engine Exhaust Systems. Polycrystalline Alumina fiber (PCF) is made by Sol-Gel method. It provides excellent resiliency and thermal stability at high temperature. Because of the high temperature capability and unique diameter distribution, MAFTEC (that is a commercial PCF product) provides excellent performance and safety advantages. Needled PCF mat has superior durability that adds valuable protection that is favorable for Ultra Thin Substrate (UTS). It has excellent mechanical strength - including tensile strength, anti-peeling stress, and air force erosion resistance due to the strong structure created by an interlocking network of fibers. Consequently, MAFTEC has the best potential for low and zero-binder mats.

This paper describes the origin of MAFTEC's properties, reviewing its raw materials and production process. Additionally, a review of testing results compared with other materials as outlined below.

• Thermal Shrinkage at high temperature
• Tensile and peeling strength
• Air force erosion durability.
• Static pressure performances
• Cycle-pressure performances
• Estimated residual pressure after long term
• Diameter distributions

The test procedures are explained in detail. The analysis of the data and conclusions for performance differences are discussed.