Catalytic Converters

Catalytic converters can be evaluated using a vast array of test methods, including thermal/vibration durability, heat aging, cone fatigue, weld fatigue, and heat shield evaluation. A number of vibration profiles can be utilized including sine, random and field data replication using your vehicle drive file. Thermal profiles can range from steady state to water quench to air quench using our unique cold air bypass system to rapidly thermal cycle converters. Substrate depth measurements can be recorded periodically to identify mat erosion for ceramic catalytic converters or telescoping of metallic catalytic converters.

Exhaust Joints

Exhaust joints are subjected to cyclic loading/vibration and thermal inputs to simulate vehicle conditions. Water (w or w/o salt) and air quenches can be used to further simulate driving conditions. The exhaust joints are then evaluated against pre and post leak-rate criteria along with some dimensional gap measurements. Maximum capabilities for exhaust gas temperatures and flow-rates are 1200°C and 300cfm respectively. This type of test is used to validate flanges, fasteners, welds, seals, clamps, etc. anything that has to do with an exhaust joint from the manifold back.

Mufflers

Thermal and vibration inputs can be used to simulate vehicle conditions for exhaust mufflers. Whether your goal is aesthetic or functional durability, our testing capabilities can ensure your muffler meets your criteria. Thermal aging tests can illustrate aesthetic discoloration on chromed parts while vibration and temperature inputs can validate durability reliability. Loading conditions at both ambient and exhaust temperatures can test the integrity of welds and hangar brackets.

Flex Pipes / Catalysts

Flex pipes and flex catalysts can be subjected to various compound movements in the vehicle. Several actuators or unique fixturing can be used to recreate these compound deflections in the laboratory. When combined with our high temperature exhaust simulator, fatigue durability can be evaluated with confidence.

Oxygen Sensors

When exposed to high temperatures and vibration whether it’s a swept sine, random or sine-on-random input oxygen sensors can exhibit intermittencies in the electrical signal. Data acquisition can be used in the laboratory to detect these intermittencies when driving parameters are simulated.

Heat Shields

Thermal and vibration inputs can be used to validate the durability of heat shield welds. The vibration is typically input with an electro-dynamic shaker. Our unique water spray system allows you to quench the component while subjected to the vibration profile you selected.

Fastener Evaluations

Exhaust joints are subjected to cyclic loading/vibration and thermal inputs to simulate vehicle conditions. Water (w or w/o salt) and air quenches can be used to further simulate driving conditions. The exhaust joints are then evaluated against pre and post leak-rate criteria along with some dimensional gap measurements. Maximum capabilities for exhaust gas temperatures and flow-rates are 1200°C and 300cfm respectively. This type of test is used to validate flanges, fasteners, welds, seals, clamps, etc. anything that has to do with an exhaust joint from the manifold joints (link.)

Flange Evaluations

Exhaust joints are subjected to cyclic loading/vibration and thermal inputs to simulate vehicle conditions. Water (w or w/o salt) and air quenches can be used to further simulate driving conditions. The exhaust joints are then evaluated against pre and post leak-rate criteria along with some dimensional gap measurements. Maximum capabilities for exhaust gas temperatures and flow-rates are 1200°C and 300cfm respectively. This type of test is used to validate flanges, fasteners, welds, seals, clamps, etc. anything that has to do with an exhaust joint from the manifold joints (link.)

Water Quench

Components can be water quenched to perform a thermal shock. Our versatile test cells can accommodate various forms of water quenching from spraying in a variety of patterns with or without salt to submersion at varying levels.

Water Submersion

Components can be water quenched to perform a thermal shock. Our versatile test cells can accommodate various forms of water quenching from spraying in a variety of patterns with or without salt to submersion at varying levels.

Salt Spray

Salt can be added to water spray and submersion quenches to accelerate corrosive effects on exhaust components.

Extensive Temperature Studies

Our 15-channel (expandable to 240-channel) temperature data acquisition system makes it possible to record many temperatures simultaneously on a component or exhaust system. Additionally, thermocouples can be welded on-site when and where you need them.

Field Failure Analysis / Test Development

We specialize in meeting your needs any time and every time. If you don’t have a test to evaluate your component or system, we’ll help you develop one. Whether it’s a bench test for a particular exhaust joint or recreating a failure on catalytic converters, we have the equipment and the experience to help you develop your test plan.

High Temperature Heat Aging

Whether aging catalysts, chromed mufflers or doing accelerated corrosion testing on exhaust joint components, our high temperature exhaust simulators can achieve the temperature and flow rates you need. Profile control and external event triggering (air quench, water quench, etc.) make it possible to run the thermal cycle that meets your needs.

Leak Analysis

Our leak test equipment has the ability to measure leak rates as low as 20mL per minute. Leak rates are automatically compensated for standard atmospheric pressure and temperature conditions and reported in standard liters per minute.