Abstract: A method for additive manufacturing a metal or ceramic part including forming a green metal or ceramic body having sacrificial supports present on at least one surface of the green body and placing the green body into a heating chamber such that the sacrificial supports support the green body. The green body is heated to remove a binder, forming a brown body. The brown body is sintered forming a metal or ceramic part, and the sacrificial supports are positioned to support the brown body during sintering. The sacrificial supports are then removed from the metal or ceramic part.

Abstract: One embodiment is a heat exchanger comprising a shell surrounding a first fluid plenum, a plurality of flow chamber walls positioned inside the shell, and a diffuser positioned inside the shell. The plurality of flow chamber walls: at least partially define a plurality of first fluid radial flow channels in flow communication with a first fluid inlet and the first fluid plenum, at least partially define a plurality of second fluid axial flow channels in flow communication with a second fluid inlet, and comprise an arcuate shape and arranged in an array to at least partially define arcuate shapes of the first fluid radial flow channels and the second fluid axial flow channels. The diffuser includes a diffuser surface at least partially defining a diffusion flow path from the first fluid inlet and the plurality of first fluid radial flow channels.

Abstract: A polygonal substrate assembly includes a polygonal substrate housing, a substrate, and a compressible mat. The compressible mat is positioned about the substrate and the substrate is press-fit within the polygonal substrate housing with the compressible mat. The polygonal substrate housing may include a sidewall having a concave portion. The polygonal substrate housing may include a substrate installation portion that flares out from a main sidewall at an end of the polygonal substrate housing. The polygonal substrate housing may be formed from a plurality of substrate housing components welded together. The polygonal substrate housing can include one or more stiffening ribs. Several polygonal substrate assemblies may be combined and coupled together to form an array in various geometric configurations.

Abstract: A doser mounting bracket for coupling a doser to an exhaust gas aftertreatment system component having a sidewall and an exhaust gas aftertreatment system component opening includes a lower surface, an engagement wall, a central structure, an upper surface, and an attachment structure. The lower surface is configured to be held in a position opposing the sidewall. The engagement wall extends from the lower surface. The central structure has an opening that extends therethrough and includes a centering structure that extends from the lower surface and is configured to be received within the exhaust gas aftertreatment system component opening. The attachment structure extends from the upper surface and is configured to be coupled to the doser. The engagement wall is configured to separate the lower surface from the sidewall when the engagement wall interfaces with the sidewall such that a pocket is formed between the engagement wall, the centering structure, and the lower surface.

Abstract: A doser mounting bracket for coupling a doser to an exhaust gas aftertreatment system component having a sidewall and an exhaust gas aftertreatment system component opening includes a lower surface, an engagement wall, a central structure, an upper surface, and an attachment structure. The lower surface is configured to be held in a position opposing the sidewall. The engagement wall extends from the lower surface. The central structure has an opening that extends therethrough and includes a centering structure that extends from the lower surface and is configured to be received within the exhaust gas aftertreatment system component opening. The attachment structure extends from the upper surface and is configured to be coupled to the doser. The engagement wall is configured to separate the lower surface from the sidewall when the engagement wall interfaces with the sidewall such that a pocket is formed between the engagement wall, the centering structure, and the lower surface.

Abstract: A reductant insertion assembly for inserting a reductant into an aftertreatment system includes: a pump assembly comprising a pump that includes a pump outlet; a first metering assembly fluidly coupled to the pump outlet, the first metering assembly comprising a first metering manifold; and a second metering assembly fluidly coupled in series with the pump, the second metering assembly being a separate structure from the first metering assembly and comprising a second metering manifold removably coupled to the first metering manifold. The pump is configured to pump the reductant to the first metering assembly, and to the second metering assembly via the first metering assembly.

Abstract: A controller for a dosing module including a pump, an inlet manifold coupled to the pump, a nozzle, an outlet manifold coupled to the nozzle, a first branch coupled to the inlet manifold and the outlet manifold and having a first flow restrictor and a first valve, a second branch coupled to the inlet manifold and the outlet manifold and having a second flow restrictor and a second valve, and a sensor coupled to the inlet manifold and the outlet manifold, includes an input/output interface and a processing circuit. The input/output interface is configured to electronically communicate with the first valve and the second valve. The processing circuit configured to selectively cause the first valve to be in a first valve first position, in which the first valve facilitates fluid communication from the inlet manifold to the outlet manifold through the first branch, and a first valve second position.

Abstract: A reductant insertion system for inserting reductant into an aftertreatment system via a reductant injector comprises a reductant insertion assembly comprising a pump operatively coupled to the reductant injector via a reductant delivery line. A compressed gas source is operatively coupled to the reductant injector and provides a compressed gas to the reductant injector for gas assisted delivery of the reductant. A controller is operatively coupled to the compressed gas source and the reductant insertion assembly and configured to determine whether there is a reductant demand for the reductant. In response to there being no reductant demand, the controller stops the pump and activates the compressed gas source for a predetermined time so as to provide compressed gas to the reductant injector at a pressure sufficient to force reductant contained in the reductant injector upstream towards the reductant insertion assembly via the reductant delivery line while the pump is stopped.

Abstract: A dosing module includes a frame assembly, a first manifold, a first dosing tray, and a first rail assembly. The frame assembly includes a plurality of panels. The first manifold is coupled to one of the plurality of panels. The first manifold is configured to separately receive air and reductant. The first manifold includes a first connector extending from the first manifold. The first dosing tray includes a first base panel, a second manifold, and a second connector. The second manifold is coupled to the first base panel. The second manifold is configured to separately receive air and reductant from the first manifold and to provide the air and the reductant back to the first manifold. The second connector extends from the second manifold. The second connector is configured to be selectively coupled to the first connector. The first rail assembly includes a first member and a second member.

Abstract: An aftertreatment component's shape, entrance geometry, and/or position within an aftertreatment assembly can be modified for local and/or bulk exhaust flow control. In some implementations, a body of the aftertreatment component has a non-circular cross-section, a non-circular opening, and/or a variable face geometry. The non-circular cross-section and/or opening can be of a variety of different shapes.

Abstract: A reductant insertion assembly for inserting a reductant into an aftertreatment system includes: a pump assembly comprising a pump that includes a pump outlet; a first metering assembly fluidly coupled to the pump outlet, the first metering assembly comprising a first metering manifold; and a second metering assembly fluidly coupled in series with the pump, the second metering assembly being a separate structure from the first metering assembly and comprising a second metering manifold removably coupled to the first metering manifold. The pump is configured to pump the reductant to the first metering assembly, and to the second metering assembly via the first metering assembly.

Abstract: A reductant insertion assembly for inserting a reductant into an aftertreatment system comprises a pump assembly including a pump. A first metering assembly is fluidly coupled to the pump. A second metering assembly is fluidly coupled to first metering assembly in series with the pump. The pump is configured to pump the reductant to the first metering assembly, and to the second metering assembly via the first metering assembly, such that a first reductant pressure in the first metering assembly is equal to a second reductant pressure in the second metering assembly.

Abstract: Methods of combining catalytic plates into an assembly of a non-monolithic structure, such as a catalyst substrate or filter assembly, of an exhaust aftertreatment system. A plurality of plates may be disposed within a housing in an arrangement that may define a catalytically active volume of a substrate. Each of the plurality of plates may be single-curved or multiple-curved and/or may be represented by three-dimensional nestable structures. The arrangement of plates may be configured such that the flow is axial, radial, or represented by a hybrid, multi-segment intake path. The plurality of plates may be arranged such that they are configured to receive targeted amounts of coating agent, which may differ among the plates.

Abstract: A controller for a dosing module including a pump, an inlet manifold coupled to the pump, a nozzle, an outlet manifold coupled to the nozzle, a first branch coupled to the inlet manifold and the outlet manifold and having a first flow restrictor and a first valve, a second branch coupled to the inlet manifold and the outlet manifold and having a second flow restrictor and a second valve, and a sensor coupled to the inlet manifold and the outlet manifold, includes an input/output interface and a processing circuit. The input/output interface is configured to electronically communicate with the first valve and the second valve. The processing circuit configured to selectively cause the first valve to be in a first valve first position, in which the first valve facilitates fluid communication from the inlet manifold to the outlet manifold through the first branch, and a first valve second position.

Abstract: A dosing module includes: a frame assembly comprising a plurality of panels; a first manifold configured to separately receive reductant and air and including: a first connector, and a second connector; and a dosing tray including: a base panel, a second manifold configured to separately receive the air and the reductant and provide the air and the reductant back to the first manifold, a third connector selectively coupled to the first connector, and a fourth connector selectively coupled to the second connector. When the third connector is coupled to the first connector and the fourth connector is coupled to the second connector, the reductant or air is routed to the first connector, from the first connector to the third connector, from the third connector to the fourth connector, from the fourth connector to the second connector, and from the second connector outside of the dosing module.

Abstract: A dosing module includes an inlet manifold, an outlet manifold, a first branch, and a second branch. The inlet manifold is configured to selectively receive reductant from a pump. The outlet manifold is configured to selectively provide the reductant to a nozzle. The first branch is coupled to the inlet manifold and the outlet manifold. The first branch is configured to selectively provide the reductant from the inlet manifold to the outlet manifold. The first branch includes a first flow restrictor configured to restrict the reductant as the reductant is provided to the outlet manifold. The second branch is coupled to the inlet manifold and the outlet manifold. The second branch is configured to selectively provide the reductant from the inlet manifold to the outlet manifold separately from the first branch. The second branch includes a second flow restrictor that is configured to restrict the reductant.

Abstract: A reductant insertion system for inserting reductant into an aftertreatment system via a reductant injector comprises a reductant insertion assembly comprising a pump operatively coupled to the reductant injector via a reductant delivery line. A compressed gas source is operatively coupled to the reductant injector and provides a compressed gas to the reductant injector for gas assisted delivery of the reductant. A controller is operatively coupled to the compressed gas source and the reductant insertion assembly and configured to determine whether there is a reductant demand for the reductant. In response to there being no reductant demand, the controller stops the pump and activates the compressed gas source for a predetermined time so as to provide compressed gas to the reductant injector at a pressure sufficient to force reductant contained in the reductant injector upstream towards the reductant insertion assembly via the reductant delivery line while the pump is stopped.

Abstract: A dosing module includes: a frame assembly comprising a plurality of panels; a first manifold configured to separately receive reductant and air and including: a first connector, and a second connector; and a dosing tray including: a base panel, a second manifold configured to separately receive the air and the reductant and provide the air and the reductant back to the first manifold, a third connector selectively coupled to the first connector, and a fourth connector selectively coupled to the second connector. When the third connector is coupled to the first connector and the fourth connector is coupled to the second connector, the reductant or air is routed to the first connector, from the first connector to the third connector, from the third connector to the fourth connector, from the fourth connector to the second connector, and from the second connector outside of the dosing module.

Abstract: A reductant insertion assembly for inserting a reductant into an aftertreatment system comprises a pump assembly including a pump. A first metering assembly is fluidly coupled to the pump. A second metering assembly is fluidly coupled to first metering assembly in series with the pump. The pump is configured to pump the reductant to the first metering assembly, and to the second metering assembly via the first metering assembly, such that a first reductant pressure in the first metering assembly is equal to a second reductant pressure in the second metering assembly.

Abstract: A polygonal substrate assembly includes a polygonal substrate housing, a substrate, and a compressible mat. The compressible mat is positioned about the substrate and the substrate is press-fit within the polygonal substrate housing with the compressible mat. The polygonal substrate housing may include a sidewall having a concave portion. The polygonal substrate housing may include a substrate installation portion that flares out from a main sidewall at an end of the polygonal substrate housing. The polygonal substrate housing may be formed from a plurality of substrate housing components welded together. The polygonal substrate housing can include one or more stiffening ribs. Several polygonal substrate assemblies may be combined and coupled together to form an array in various geometric configurations.