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Development of Material for Lightweight Catalytic Converter

Article of Honda R&D Technical Review Vol.26 No.1

Summary

High-strength ferritic stainless steel HSS430CU has been developed as a material for use in catalytic converters. This material has superior strength at elevated temperatures and excellent press-forming properties.
HSS430CU does not contain the expensive element Mo that is normally added to the conventional high-strength ferritic stainless steel that is represented in Type444. Instead, Cu is added, which achieves equal or better high-strength properties. This material combines both the workability and strength properties required for catalytic converters. These properties are achieved as follows: superior workability is ensured by
incorporating Cu, which is required for high strength, into solid solution when the materials are still raw materials, prior to press-forming; and high strength is ensured once the part is mounted in the vehicle, when heat energy is received as a result of exhaust gas, causing the Cu that was incorporated into solid solution to precipitate as fine ε-Cu crystals.
When this material was used in the catalytic converter for the 2014 model year FIT, the high-strength-providing properties of the material were utilized to reduce the plate thickness by 20% or greater. In addition, that superior workability enabled parts that had previously been formed as two pieces to be integrated into one piece, and it reduced weight while simultaneously cutting costs as well.

Reference

(1) Inoue, Y., Kikuchi, M.: Present and Future Trends of Stainless Steel for Automotive Exhaust System, Nippon Steel Technical Report, No. 88, p. 62-69 (2003)
(2) Miyazaki, A., Hirasawa, J., Furukimi, O.: Ferritic Stainless Steel for Automotive Exhaust Systems - High Heat-Resistant Ferritic Stainless Steel with High Formability for Automotive Exhaust Manifolds: “JFE-MH1” -, JFE Technical Report, No. 4, p. 61-66 (2004)
(3) Tomita, T., Oku, M.: Development of Cu Bearing Ferritic Stainless Steel, NSSEM-C, Nisshin Seiko Giho, No. 90, p. 30-39 (2009) (In Japanese)
(4) Yazawa, Y., Kato, Y., Ujiro, T.: Ferritic Stainless Steel Sheets with Deep Drawability, JFE Technical Report, No. 20, p. 72-78 (2008) (In Japanese)
(5) Ishimaru, E., Takahashi, A., Ono, N.: Effect of Material Properties and Forming Conditions on Formability in High-Puerility Ferritic Stainless Steels, Nippon Steel Technical Report, No. 99, p. 26-32 (2010)
(6) Yazawa, Y., Kato, Y., Kobayashi, M.: Development of Ti-bearing High Performance Ferritic Stainless Steels “R430XT, RSX-1”, Kawasaki Steel Technical Report, Vol. 30, No. 2, p. 93-98 (1998) (In Japanese)
(7) Matsuho MIYASAKA, Lecture on Corrosion and Corrosion Protection of Seawater Pumps - Part 5: Corrosion and Corrosion Protection of Stainless Steels and Ni-Resist Irons -, Ebara Jiho, No. 224, p. 28-37 (2009) (In Japanese)
(8) Uchida, K., Minato, T.: Engineering Development in Resistance to Oxidation at High Temperature for Exhaust Manifold with Resistance to High Temperature, CALSONIC KANSEI TECHNICAL REVIEW, Vol. 8, p. 62-66 (2011) (In Japanese)

Author (organization or company)

Osamu SUZUKI(Automobile R&D Center)

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