Abstract
For the sake of environmental reasons, additive manufacturing of catalytic converters has been an attractive topic in both computational research and product development fields within the last few years. With respect to structured catalysts, monolithic designs manage convenient characteristics by providing a large surface area for catalytic reactions within a defined volume. Because of manufacturing limitations, conventional metallic monolithic geometries were limited to sinusoidal channels. Accumulation of the catalyst and washcoat in the corners of sinusoidal channels have negative influences on the washcoat geometry and mass-transfer. These reasons together with high manufacturing costs had limiting effects on expanding applications of metallic monoliths. With the emergence of rapid prototyping technologies, complex unity structures of metallic monoliths can be printed at once. Although flexibility in design and ease in fabrication both are satisfied with additive manufacturing, still operational conditions and reaction requirements must be met for approval of any prototypes. This research uses a multidisciplinary approach to study monolithic designs suitable for a specific reactor size. Besides, these designs must be 3D-printable and suitable for washcoating. Considering design challenges and innovations in additive manufacturing of metals, relationships between mathematics, structural integrity, coating and material aspects are considered for analyzing the multi-channel monoliths.
Published Version
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