Multi-Objective Optimization of Extrusion Parameters for High-Performance Honeycomb Cordierite Ceramics via...

Area of Science:

• Materials Science
• Ceramic Engineering
• Automotive Engineering

Background:

• Diesel particulate filters (DPFs) are essential for reducing emissions from diesel engines.
• Cordierite is a common ceramic material used in DPFs due to its thermal properties.
• Optimizing the manufacturing process is key to enhancing DPF performance and durability.

Purpose of the Study:

• To determine optimal processing parameters for cordierite DPFs.
• To investigate the effect of sintering temperature and composition on DPF properties.
• To achieve a balance between porosity, strength, and thermal shock resistance.

Main Methods:

• Extrusion technique using pure cordierite powder, organic binders, sodium silicate aids, and pore formers.
• Orthogonal test method for multi-objective, multi-factor optimization.
• Statistical analysis to identify key process variables and their impact.

Main Results:

• Sintering temperature was identified as the most significant factor influencing DPF performance.
• Optimal parameters: 3 h holding time, 10 wt.% pore former, 12 wt.% sintering aid, and 1150 °C sintering temperature.
• At 1150 °C, samples exhibited high porosity (56.04%), compressive strength (5.88 MPa), bending strength (13.10 MPa), and low CTE (1.82 × 10⁻⁶/°C).

Conclusions:

• The optimized cordierite DPFs demonstrate excellent thermal shock resistance and filtration efficiency.
• The study provides a reference for designing honeycomb ceramics with optimal liquid phase content.
• The findings show great potential for advanced DPF applications in emission control systems.