Ceramics Expo 2017 was chosen for the launch of a new range of kiln furniture from Morgan Advanced Materials. Suited to the production of catalytic converters and diesel particulate filters (DPFs), Halsic-N is a nitride-bonded silicon carbide with a microstructure that offers increased mechanical strength and greater durability than the typical materials used for firing honeycomb structures. It is an advancement of Morgan’s Halsic-R range, designed to have an increased lifespan, with enhanced refractory properties such as resistance to oxidation and thermal shock. The material is being used for the firing of ceramic porcelain throughout Europe, but Ceramics Expo marked the first time Morgan has made Halsic-N available to the U.S. market, where the production of catalytic converters and DPFs is accelerating.

U.S. legislation concerning vehicle emissions is increasingly making the role of catalytic converters and DPFs more important for diesel vehicles, where the nation is working with the rest of the world to reduce the release of harmful gases in the form of vehicle emissions. Key to the success of these efforts is the dense honeycomb structure, which is manufactured by firing ceramic material. This unique structure provides the maximum surface area on which chemical reactions take place, using the least amount of catalyst. This facilitates the conversion of carbon monoxide and hydrocarbons to carbon dioxide, and nitrogen oxide to nitrogen gas. In order to create the honeycomb ceramic structure, the material must be fired at high temperatures of up to 2,732°F (1,500°C), requiring durable refractory materials.

“Throughout the U.S., we are seeing an increase in the production of DPFs and catalytic converters, and the design of such components is becoming more sophisticated all the time,” said Michael Rozumek, Ph.D., R&D director. “These components used to consist of only one filter per catalytic converter, however today’s models have two or three separate discrete filters, prompting demand for the firing process.

“Halsic-N is our response to this demand. A material with a flexural strength of 160 MPa, improved oxidation resistance and resistance to creep deformation, it delivers all of the key performance attributes demanded by kiln users. Morgan also has the capability to form shapes to the exact dimensions required by customers, delivering a material that can be relied upon for repeated use during rapid heating and cooling.”
 

 For more information, visit www.morgantechnicalceramics.com.