Abstract: A system for controlling center-to-outer flow distribution of extrudate source material through an extrusion die suitable for production of a honeycomb extrudate, and a method for fabricating a honeycomb extrudate, are provided. Sequentially arranged first and second plates define first and second pluralities of openings through which extrudate source material may flow, wherein at least some openings of the second plurality of openings arranged at different radial positions differ in area. Relative movement between the first plate and the second plate may be effectuated to adjust overlap between corresponding openings of the plates, thereby adjusting a center-to-outer flow distribution of extrudate source material through an extrusion die arranged downstream of the first and second plates.

Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.

Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.

Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.

Abstract: Systems and methods for real-time, closed-loop shape control of extruded ceramic honeycomb structures are disclosed. Methods include extruding batch material through an extruder barrel and through an extruder die using at least one extrusion screw to form the extrudate, and measuring a shape of the extrudate immediately adjacent the die. The batch material water content is determined or measured, at least one of the extruder barrel and screw temperature are measured, and the extrusion screw rotation rate are measured. At least one of the batch material water content, barrel temperature, screw temperature and rotation rate is adjusted to maintain the extrudate shape to within a select tolerance.

Abstract: A method of making ceramic bodies having reduced shape variability. Such ceramic bodies include extruded-to-shape substrates and diesel particulate filters. Principal components analysis is used to generate a small number of uncorrelated or independent components from a larger set of inter-correlated measurements. The uncorrelated components can then be used during the forming process to control the shape of ceramic bodies and reduce variability of such shapes. A method for quantifying and subsequently reducing the shape variability of is also described.

Abstract: A method of minimizing distortion in a glass sheet manufacturing process wherein the stress in a parent sheet of glass is measured along each edge of the sheet. The stress data is then used to develop a distortion predictor for predicting the in-plane distortion which sub-sheets of the parent sheet are likely to exhibit when the parent sheet is cut into pre-determined sizes. The in-plane distortion may be predicted based on criteria established by the glass manufacturer, or supplied by an original equipment manufacturer (OEM).