Abstract: An apparatus, system, and method are disclosed for determining a time-temperature history of an aftertreatment device. The apparatus includes an aftertreatment device comprising a substrate, and at least one thermal monitoring member (TMM) in thermal contact with the substrate. The TMMs may comprise a material that exhibits an electrical resistivity change at temperature over time. The apparatus may include a controller configured to measure the electrical resistivity of at least a portion of the TMMs, and to determine a thermal history based on the electrical resistivity measures.

Abstract: An inlet face for an aftertreatment device that prevents and/or eliminates face-plugging for a passageway where the inlet face is disposed. The inlet face includes a particular end surface disposed on an outer surface at the end of a substrate. The end surface includes at least one of a three-dimensional topographical configuration disposed at the end of the substrate, a chemical coating applied on the end of the substrate, or both a three-dimensional topographical configuration disposed on the end of the substrate and a chemical coating applied on the three-dimensional topographical configuration. As one example, the inlet face can be helpful in preventing carbonaceous fouling, which can result from engine exhaust material, such as carbon soot and other engine exhaust by-products.

Abstract: An apparatus, system, and method are disclosed for dispersing heat within a particulate filter. The apparatus may include various devices for dispersing heat from a high risk portion of the particulate filter by delaying heat generation, by conducting generated heat out of the high risk portion, by absorbing the heat generated into molecular energy rather than temperature, by shifting some of the heat burden away from the particulate filter to other devices in an aftertreatment system, or out of the aftertreatment system. The delaying device may be a reduction of catalyst loading within portions of the particulate filter. The conducting device may be a plurality of thermal conduits within portions of the particulate filter. The absorption device may be a high heat capacity washcoat in portions of the particulate filter.

Abstract: An exhaust aftertreatment filter has a pre-stressed layer bonded to the filter body at the outer periphery and compressively axially pre-stressed in an opposite axial direction to separational axial tensile stress to counteract the latter during regenerative heating, to minimize separational fracture and cracking.

Abstract: An exhaust gas aftertreatment device for an internal combustion engine comprises an inlet configured to receive the exhaust gas, an outlet from which the exhaust gas exits the device, a first passageway defined between the inlet and the outlet, and a second passageway defined between the inlet and the outlet, wherein the second passageway is separate from the first passageway. A first aftertreatment element is disposed in the first passageway. In one embodiment, the device is a diesel oxidation catalyst device and the second passageway represents a bypass passageway. The second passageway may further have a second aftertreatment element disposed therein. In an alternative embodiment, the device is a NOx aftertreatment element, and a second aftertreatment element is disposed in the second passageway. In either case, the device includes an exhaust gas flow control mechanism configured to selectively control exhaust gas flow through the first and second passageways.

Abstract: An exhaust system for a diesel engine which includes a particulate filter for filtering a flow of engine exhaust gas includes, as part of the exhaust system, a catch basin for the collection of oxidation by-products from the particulate filter. Important in the design is to orient the particulate filter in a generally vertical orientation based upon the normal orientation of the diesel engine when in use. By vibration of the engine due in part to engine operation and due in part to vehicle vibrations, oxidation by-products shake loose from the particulate filter and fall through a connecting conduit. By positioning the catch basin below the particulate filter and connecting it to the conduit, the oxidation by-products are able to be collected in the catch basin for removal at a later time.

Abstract: An exhaust aftertreatment filter and method is provided for filtering engine exhaust. Varying cell size is provided to spread trapped contaminant particulate along a distribution pattern reducing heat concentration and the risk of melting during regeneration, to minimize hot-spot meltdown otherwise caused by high density concentration of trapped particulate during regeneration. Cell size is varied by varying volume and/or height and/or width and/or length. Tapering of cells is also provided to change the cross-sectional area from the upstream to the downstream end.

Abstract: An exhaust aftertreatment filter and method is provided for filtering engine exhaust. Varying cell size is provided to spread trapped contaminant particulate along a distribution pattern reducing heat concentration and the risk of melting during regeneration, to minimize hot-spot meltdown otherwise caused by high density concentration of trapped particulate during regeneration. Cell size is varied by varying volume and/or height and/or width and/or length. Tapering of cells is also provided to change the cross-sectional area from the upstream to the downstream end.

Abstract: A high temperature composite ceramic filter having particular use as a diesel engine exhaust filter. An aqueous slurry containing short ceramic fibers, organic fibers and a water soluble thermoplastic binder is formed into a sheet and dried. The dried sheet is then fabricated into a three-dimensional green filter structure and a binder, either a liquid solution of a thermosetting resin or a colloidal solution of a ceramic material, is applied to the filter structure to increase the temperature stability of the green structure. The filter structure is then fired at an elevated temperature sufficient to remove the organic constituents and is subsequently coated with silicon carbide by a chemical vapor deposition process to provide a composite ceramic filter having high temperature resistance, durability and improved performance.

Abstract: A microwave regenerable filter element including a filter media for filtering particulates from an exhaust gas, and a plurality of discrete heat generators disposed in the filter media, each of the plurality of discrete heat generators being adapted to absorb microwave energy and convert the microwave energy into heat. In one embodiment, the plurality of discrete heat generators may have a length dimension of substantially ½ of a microwave wavelength and a width dimension of substantially ⅛ of a microwave wavelength. In another embodiment, the plurality of discrete heat generators may be disposed in a spatial array in a manner that density of the plurality of discrete heat generators varies radially away from a central axis of the filter element. In yet another embodiment, the density of the plurality of discrete heat generators in the spatial array may also vary axially along the central axis of the filter element.

Abstract: A lube oil and fuel blending system, pumping device and method are provided which effectively, inexpensively and controllably removes used lube oil from an engine and delivers the lube oil to the fuel system for consumption within the engine. The lube oil and fuel blending system includes a fuel pumping device or injector containing a bore and a plunger reciprocally mounted in the bore for movement through a retraction stroke and an advancement stroke, each having a predetermined stroke length. A fuel drain circuit communicates with the bore at a drain location spaced a predetermined seal length axially along the bore from an outer opening of the bore through which the plunger extends. The predetermined seal length is specifically designed less than the predetermined stroke length to cause lube oil on the outer portion of the plunger to be delivered by the plunger to the fuel drain circuit at the drain location.

Abstract: A method for accurately and economically shaping a zirconia workpiece with a relatively inexpensive silicon carbide grinding wheel is provided. The grinding wheel used in the method preferably utilizes 220 mesh silicon carbide particles bound in a low porosity vitreous matrix. The grinding wheel is then rotated at a sufficient speed to implement a grinding operation, and is engaged against the zirconia workpiece at a diametral feed rate of at least 0.04 mm/sec. The method advantageously removes material from the zirconia workpiece at a high rate of speed with minimal wheel wear, and results in accurate cuts and smooth surface finishes, and also eliminates the need for dressing the wheel prior to the grinding operation.

Abstract: A wear and scuff-resistant plunger for use in high pressure fuel system components in internal combustion engines is provided. The plunger, which is formed of a high thermal expansion, high hardness ceramic with a thermal expansion coefficient preferably greater than 6.times.10.sup.-6 /.degree. C. and a hardness preferably greater than 800 Kg/mM.sup.2, maintains a desired optimum minimal diametral clearance while avoiding excessive fuel leakage and efficient plunger function without scuffing or sticking under the high axial, side and pressure loads and variable quality fuels encountered in the fuel system operating environment. Preferred high thermal expansion, high hardness ceramics are zirconia, alumina-zirconia and alumina.

Abstract: A method for accurately and economically shaping a zirconia workpiece with a relatively inexpensive silicon carbide grinding wheel is provided. The grinding wheel used in the method preferably utilizes 220 mesh silicon carbide particles bound in a low porosity vitreous matrix. The grinding wheel is then rotated at a sufficient speed to implement a grinding operation, and is engaged against the zirconia workpiece at a diametral feed rate of at least 0.04 mm/sec. The method advantageously removes material from the zirconia workpiece at a high rate of speed with minimal wheel wear, and results in accurate cuts and smooth surface finishes, and also eliminates the need for dressing the wheel prior to the grinding operation.

Abstract: A wear and scuff-resistant timing plunger for a timing assembly in a unit fuel injector for an internal combustion engine is provided. The timing plunger is formed of a high thermal expansion ceramic with a thermal expansion coefficient greater than 6.times.10.sup.-6 /.degree. C. and a hardness greater than 800 Kg/mm.sup.2, which maintains a desired diametral clearance and efficient plunger function without scuffing or sticking under the axial, tangential and pressure loads encountered in the fuel injector operating environment. Preferred high thermal expansion ceramics are zirconia, alumina-zirconia and alumina.

Abstract: A low inertia, wear-resistant needle valve assembly is provided for an internal combustion engine closed nozzle unit fuel injector. The needle valve assembly includes a needle and spring retainer subassembly made from an advanced structural ceramic, such as silicon nitride. A valve seat subassembly in the injector cup is made from a combination of metal and ceramic. The assembly materials and configuration provide maximum control over the efficiency of the injection event so that the fuel injection event can be terminated quickly, thereby allowing more effective control over exhaust emissions.

Abstract: A thermal barrier coating for metal articles subjected to rapid thermal cycling includes a metallic bond coat deposited on the metal article, at least one MCrAlY/ceramic layer deposited on the bond coat, and a ceramic top layer deposited on the MCrAlY/ceramic layer. The M in the MCrAlY material is Fe, Ni, Co, or a mixture of Ni and Co. The ceramic in the MCrAlY/ceramic layer is mullite or Al.sub.2 O.sub.3. The ceramic top layer includes a ceramic with a coefficient of thermal expansion less than about 5.4.times.10.sup.-6 .degree.C.sup.-1 and a thermal conductivity between about 1 J sec.sup.-1 m.sup.-1 .degree.C.sup.-1 and about 1.7 J sec.sup.-1 m.sup.-1 .degree.C.sup.-1.

Abstract: A ceramic link element suitable for use as a component in the drive train of an internal combustion engine is provided. The link includes a central shaft portion with opposed spherical terminal ends that contact correspondingly configured elements in the drive train. The ceramic link element is formed, preferably by injection molding, to be substantially free from flaws and to have maximum pore diameters, preferably a maximum pore diameter of 150 um or less on the shaft and 40 um or less on the spherical terminal ends, to produce a link with optimum mechanical strength. When these pore dimensions are met and the degree of sphericity of the spherical terminal ends is 20 um or less, the ceramic link exhibits increased mechanical strength, durability and reliability. A method of forming a ceramic link having the aforementioned characteristics is also provided.

Abstract: A ceramic-metallic interfacing joint assembly is disclosed. The joint assembly includes a pair of interfaced components in a highly loaded, sliding contact in which the contact stresses can be as high as 250,000 psi. Preferably, the pair of interfaced components includes a ball member and a complementarily shaped, mating socket member and is used in a diesel type internal combustion engine. One of the components is formed of a ceramic material having a density of at least 3.18 g/cm.sup.3 and the other component is formed of a metallic material. Preferably, the density of the ceramic material ranges from 3.18 g/cm.sup.3 to 3.25 g/cm.sup.3. This arrangement reduces the wear of the joint assembly in conjunction with the use of a lubricant which lubricates the components. Specifically, the metallic material is an iron based material while the ceramic material is a sintered silicon nitride. The ceramic material may be sintered with rare-earth metal oxides such as yttrium oxide.

Abstract: A ceramic particulate trap is disclosed and manufactured from a plurality of ceramic support plates each having a plurality of grooves in an upper surface and a lower surface thereof extending in a direction of fluid flow. Each groove in the upper surface of the ceramic support plate having an open upstream end and a closed downstream end while each groove in the lower surface of the ceramic support plate includes a closed upstream end and an open downstream end. A ceramic foam layer is then placed on and supported by the ceramic support plates and spans the open surface of the plurality of grooves formed in the upper surface of the support plate. The support plate being manufactured by conventional relatively inexpensive extrusion processes provides structural support for the ceramic foam layer.