Abstract: The present invention includes an automotive exhaust system including a catalytic converter having a substrate of substantial surface area and having a catalyst composition carried thereon. The catalytic converter substrate is carried in a housing extending the length of the catalytic converter substrate and conforming to the outer surfaces of the substrate and/or any mounting material. A two-wall diffuser is connected by an outer wall to the converter housing at one end and to an exhaust pipe at the other. An inner wall is spaced a distance from the outer wall and defines a diffuser portion having an inlet cross-section area less than its outlet cross-section flow area. The inner wall also defines an abrupt expansion section which is provided between the end of the diffuser section and the end of the inner wall nearest the substrate. The inner wall ends in the region between the substrate and the converter housing and is free-floating and is not rigidly connected to the converter substrate or housing.

Abstract: A disk armature for an electric, in-tank fuel pump motor is manufactured by laser welding a pair of annular disks in two concentric circles of spot welds, one near each of the inner and outer circumferences of the disks. One disk is made of malleable copper for the forming of commutator hooks and studs; the other is made of hardened copper alumina for superior wear characteristics in a sour gasoline environment. The welded disks are affixed to an insulating support and cut into segments, each having at least one weld from the inner circle and two from the outer circle. Thus the segments are each securely welded without deformation or degredation of the superior wear properties of the copper alumina disk.