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06

Modul ke:

Fakultas

Teknik

Program Studi

Teknik Mesin

Perencanaan Produk
Modul ini berisi contoh detail desain alat pembuat
spiral bahan baja lembut
Darwin Sebayang
Pembuka
Daftar Pustaka
Akhiri Presentasi

Perencanaan Produk
Contoh Detail Design

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Methodology
Perencanaan
Produk
Task

Clarification of the task

Embodiment Design

Clarify the task


Elaborate the specification

Conceptual Design

Identify essential problems


Establish function structure
Search for solution principles
Combine and firm up into concept variants
Evaluate against technical and economic
criteria

Concept

Upgrade and Improve

Specification

Develop preliminary layouts and form designs


Select best preliminary layouts
Refine and evaluate against technical and
economic criteria
Optimize and complete form design
Check for errors and cost effectiveness
Prepare the preliminary parts list and production
documents

Definitive Layout
Detail Design
Finalize details
Complete drawings and production documents
Check all documents

Pahl and Beitzs Model of Design Process.

Documentation
Solution

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Introduction
Perencanaan
Produk
What is catalytic converter?
A device located in the exhaust system of
the vehicle.
The device has been in use as an efficient
and economic solution for the reduction of
pollutants emitted by the internal combustion
engine.
The device also has been the greatest
success of the automotive industry in the field
of pollution control.

Main Function :
To reduce harmful emissions ( CO, HC,
NOx) from an internal combustion engine.
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Catalytic converter consists


of 4 major components:
Perencanaan
Produk
Catalytic converter
Casing

N2
H2 O

CO2
Catalyst

NOx

HC

CO

Substrate
Washcoat

Focus
area

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Spiral type of Catalyst Substrate
Spiral substrate is one of the substrate types
for catalytic converter that have been known in
the prior art.
The spiral structure forms the core of a
catalytic converter to provide support structure
and geometric surface area upon which the
washcoat and the catalyst are applied.

Function
To provide high geometric surface area for contacting the gas phase that
flows through the channels, with the catalyst, which is coated on the
channel walls.
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Working Principles

Corrugation
process

Spiral
process

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Combining Working Principles


1

Corrugation process

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Perencanaan
Produk
Cont..

Spiral process

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EvaluatingProduk
Principle Solution Variants
Perencanaan
Corrugation process
Variant 2 for corrugation process
Suitable force is
controlled by rotation
of pinion gear

Rotation
direction
Pinion gear as
a Tool

Direction of entering
the flat sheet metal

Rotation
direction

Side view

Driven gear as a
Die

Trapezoid shape

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Cont..
Spiral process

Variant 2 for spiral process

Die for shaping


purpose

Direction of
entering the sheet
metal
Twister for rotating the
sheet metal

Suitable force

Suitable force
Force generated by
spring

Top view

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3.0 Embodiment
Design
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Produk
Preliminary Layout

Corrugation Process
Tool and Die

Housing

3.86 mm
1.86 mm
1 mm
1 mm

Tool

Die

Arrangement for Corrugation Process


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Preliminary Layout, cont..Produk


Perencanaan

Spiral Process
Housing

Twister

Shaper

Arrangement for Spiral Process


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Definitive Layout
Perencanaan
Produk

Corrugation Process
Tool and Die

Arrangement of Corrugation Process

Housing

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Definitive Layout, cont..

PerencanaanSpiral
Produk
Process
Housing

Arrangement of Spiral Process

Twister

Shaper

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Design Analysis
1) Mechanical properties of the material

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Perencanaan
Produk
2) Calculating the Torque required for Corrugation Process
Basically, pinion gear is acting as a Tool to form a flat sheet metal into
corrugated form of sheet metal. In this design, pinion gear will generate a
bending force to form the sheet metal which is the pinion gear is rotated by
hand.
The maximum bending force will be calculated on the pinion gear in order
to achieve the forming process intention. In order to estimate the required
force for bending the flat sheet metal into corrugated sheet metal, the
following formula is used.

where,

Kbf = 1.33 for V-bending or 0.33 for edge bending


TS = Tensile strength of sheet metal = 513.6MPa
w = width of sheet metal = 50mm, 75mm and 150mm.
t = thickness of sheet metal = 0.11mm
D = die opening dimensions = 1.86mm

There have three different width of sheet metal to be calculated; there are
50mm, 75mm and 150mm.
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The following formula is used to calculate the torque required.


Fr

Pinion
gear

Ft

where, = Angle of the gear


F = The estimation of maximum
bending force
Ft = Angular force
T = Torque
d = diameter of pinion gear

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The results of torque required in different width of sheet metal

where, Wt = Angular force


d = Pinion diameter
N = number of revolution (rpm)

The required power and horsepower in different width of sheet metal

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3) Estimation of the Torque required for Spiral Process


Basically, the forming process of the spiral process is based on the rotation
of the Twister to make the sheet metal in spiral shape. In this design,
Twister will generate an amount of torque which is rotated by hand as in
following figure.
Therefore, the amount of torque should be interrelated to the required force
to form the sheet metal into spiral shape. This calculation is aided by using
Spiral Spring Design (FED9) in order to achieve the forming process
intention.

Perencanaan Produk

An overview of torque generated by Twister


Twister
Twister
Sheet metal

Sheet metal

Torque, T
Entering
direction

Entering direction

Front View

Top View
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Spiral Spring Design (FED9)


The Spiral Spring Design (FED9) can calculate a torque of spiral spring
of sheet metal. Besides, the number of rotation and length also can be
obtained.
The dimensions of the spiral spring design

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The summarization of torque required with different widths


and diameters.

Graph of torque versus


diameter with different widths
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4) Finite Element Simulation Approach

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Perencanaan
Produk
[1] Forming Analysis
on the Selected Forming Area
Flat sheet metal

Corrugated sheet metal

Corrugated sheet
metal in spiral shape

Corrugated sheet metal in


spiral shape

Corrugated sheet metal

Forming area

Trapezoid cell of corrugation

Forming area

Spiral shape of corrugated sheet metal


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[2] Forming Analysis on Representative of Forming Area for Corrugation Process

Pinion gear

Punch

Die
Driven
gear

1mm
Width = 15mm

Punch

Geometric
modeling

Blank

Die

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[4] Results of Forming Analysis on Representative of Forming Area for


Corrugation Process

Deformed geometry of the Blank


Finite Limit Diagram (FLD)
of the Blank

Thickness of the formed Blank


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[5] Forming Analysis on Representative


of Forming Area for Spiral Process
Perencanaan
Produk

Modeling setup for forming analysis of


spiral process
PUNCH
BLANK

The dimensions of the tooling

Geometric
modeling
DIE

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[7] Results of Forming Analysis on Representative of Forming Area for


Spiral Process

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Forming analysis on layer with diameter of 20mm

a) Deformed geometry of the Blank


b) Finite Limit Diagram (FLD) of the Blank

c) Thickness of the Blank


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Forming analysis
on layer with diameter of 50mm
Perencanaan
Produk

a) Deformed geometry of the Blank


b) Finite Limit Diagram (FLD) of the Blank

c) Thickness of the Blank


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Forming analysis on layer with diameter of 100mm

a) Deformed geometry of the Blank


b) Finite Limit Diagram (FLD) of the Blank

c) Thickness of the Blank


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Perencanaan Produk
Then, the springback factors were calculated to generate a rule of thumb of
springback factor and was used to obtain the required unloaded diameter of the
spiral shape by setting the loaded diameter while the forming process
performed.

Half view of the outer layer


of the specimens

Summarization of the
result obtained
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4.0 Detail Design


The following is the detail specification of the designed apparatus in which
consists of Corrugated Tool for corrugation process and Spiral Tool for
spiral process.
4.1 Corrugated Tool Specification

4.2 Spiral Tool Specification

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Daftar Pustaka
1)Pischinger, S. (2004). The future of vehicle propulsion combustion engines and
alternatives. Topics in Catalysis. Vols. 30/31. pp. 5-16
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A: General 221. pp. 443-457.
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Converter Modeling as a Modern Engineering Design Tool. ASME Journal of
Engineering for Gas Turbines and Power.
5)Pontikakis, G. N. (2003). Modeling, Reaction Schemes and Kinetic Parameter
Estimation in Automotive Catalytic Converters and Diesel Particulate Filters. PhD
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6)Konstantas, G. S. (2006). Development and Application of a Computer Aided
Engineering Methodology Supporting the Design Optimization of Automotive Exhaust
Treatment System. PhD Thesis. UTh/MIE No.23.
7)Searles, R.A. (2002). Contribution of Automotive Catalytic Converters. In Hans Bode
(Ed.) Material Aspects in Automotive Catalytic Converters. Germany: Wiley-VCH. Pp. 316.
8)Bruck, R., (2002). Development Status of Metal Substrate Catalyst. In Hans Bode (Ed.)
Material Aspects in Automotive Catalytic Converters. Germany: Wiley-VCH. Pp. 19-30.
9)Rajadurai, S., Jacob, S., Serrel, C., Morin, R. and Kircanski, Z. (2006). Wiremesh
Substrates for Oxidation, TWC and SCR Converters. Advanced Propulsion & Emission.
Pp. 97-105
10)Shamim, T. and Shen, H., (2003). Effect of Geometric Parameters on the Performance
of Automotive Catalytic Converters. International Journal of Science and Technology 14.
pp. 15-22.
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Daftar Pustaka
11)Sukonnik, I. M., Chang, S. and Jha, B. (1997). DuraFoil ICR-a New Material for
Catalytic Converter Substrates. in Hans Bode (Ed.) Material Aspects in Automotive
Catalytic Converters. Deutsche Gesellschaft: Willey-vch. Pp. 93-97.
12)Nicholls, J. R. and Quadakkers, W. J. (1997). Materials Issues Relevant to the
Development of Future Metal Foil Automotive Catalytic Converters. in Hans Bode (Ed.)
Material Aspects in Automotive Catalytic Converters. Deutsche Gesellschaft: Willey-vch.
Pp. 31-48.
13)Bode, H. and Guist, C. (2001). Lifetime Predictions of Uncoated Metal-Supported
Catalysts via Modeling and Simulation, based on Reliable Material Data. in Hans Bode
(Ed.) Material Aspects in Automotive Catalytic Converters. Deutsche Gesellschaft:
Willey-vch. pp. 134-143.
14)Muller-Haas, K. and Rice, M. (2005). Innovative Metallic Substrates for Exhaust
Emission Challenges for Gasoline and Diesel Engines. SAE Jounals, 2005-01-3851.
15)Bollig, M., Liebl, J., Zimmer, R., Kraum, M., Seel, O., Siemund, S., Bruck, R.,
Diringer, J. and Maus, W. (2004). Next Generation Catalysts are Turbulent: Development
of Support and Coating. SAE Journals, 2004-01-1488.
16)Lylykangas, R. and Tuomala, H. (2001). A New Type of Metallic Substrate. in Hans
Bode (Ed.) Material Aspects in Automotive Catalytic Converters. Deutsche Gesellschaft:
Willey-vch. pp. 152-170.
17)Umehara, K., Yamada, T., Hijikata, T., Ichikawa, Y. and Katsube, F. (1997). Effective
catalyst layout for ultra thin-wall and high cell-density ceramic substrate. SAE
International paper No. 973118.
18)Chang, C., Chen, L. and Jha, B. (2001). Oxidation Induced Length Change of Thin
Gauge Fe-Cr-Al Alloys. in Hans Bode (Ed.) Material Aspects in Automotive Catalytic
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19)Campbell, M.G. and Martin, E.P. (1995). Substrate Selection for a Diesel Catalyst.
International Congress and Exposition Detroit, Michigan. SAE Journal: 950372.
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Daftar Pustaka
20)Wahlstrom, E. and Olsson, S. (1997). Effects of thickness, its tolerances and the
metallurgical process accuracy on the oxidation life time of foil strip for catalytic
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Werkstoff-Informationsgesellschaft. Pp. 69-77.
21)Ball, D., Zammit, M. G. and Mitchell, G. C. (2007). Effects of Substrate Diameter and
Cell Density FTP Performance. SAE Paper 2007-01-1265.
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Buslaev, Y and Montano, R. (2000). Thin-Walled Monolithic Metal Oxide Structures
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Daftar Pustaka
30)Kolb-Telieps, A., Klower, J., Hojda, R. and Heubner, U. (1997). A New Production Technique for
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Daftar Pustaka
41)Boljanovic, V., (2004) Sheet Metal Forming Processes and Die Design, Industrial
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Achievements
Publications
[1] Paper published and presented at International Conference on
Mechanical and Manufacturing Engineering 2008 (ICME2008)
on 21-23 May 2008 at Puteri Pacific Johor Bahru, conducted by
FKMP, UTHM.
[2] Paper published and presented at International Conference on
Advances in Mechanical Engineering ICAME 2009 on 24-25
June 2009 at Shah Alam, Malaysia conducted by FKM, UiTM.
Awards
[1] Second place in Pertandingan Poster Penyelidikan Terbaik
for category of Poster Sarjana secara Penyelidikan organized by
CGS, UTHM.
[2] Bronze medal in Research and Innovation Festival, R&I Fest
'08, for product based category organized by RMIC, UTHM.
[3] Silver award in '20th International Invention, Innovation and
Technology Exhibition (ITEX09)', for Industrial Design category.
Patent pending

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Perencanaan Produk
Aktifitas:
Bahas detail desain projek anda.
Pembahasan dilakukan pada minggu
ke 7.

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Daftar Pustaka

Quadakkers, W.J., and Bennet, M.J. (1994). Materials Science and Technology, 10, pp.126-132.
Amano, T., Watanabe T., and Michiyama, K., (2000). Oxidation of Metals, 53, Nos. 5/6, pp. 30-35.
S. Rajadurai, S. Jacob, C. Serrel, R. Morin, and Z. Kircanski, "Wiremesh substrate for oxidation, TWC and
SCR converters," Advanced Propulsion & Emissionet, 2006, pp.97-105.
K. Oouchi, K. Shibata and K. Nishizawa, "Development of thinnest wall catalyst substrate," SAE Paper,
2002-01-0358, 2002.
Kolb-Telieps, J. Klower, R. Hojda, and U. Heubner, "A new production technique for FeCrAl," in Material
Aspect in Automotive Catalytic Converters, H. Bode, Ed, Werkstoff-Informationsgesselschaft, 1997, pp.99104.
K. Solntsev, E. Shustorovich, S. Myasoedov, V. Margunov, A. Chernyavsky, Y. Buslaev, and R. Montano,
"Thin-walled monolithic metal oxide structures made from metals, and method for manufacturing such
structures, United States Patent, No. 6,051,203, 2000.
H. Bode, "Lifetime predictions of uncoated metal-supported catalysts via Modelling and simulation, based
on reliable material data," in Material Aspects in Automotive Catalytic Converters, H. Bode, Ed. Germany:
Wiley-VCH, 2002, pp. 134-143.
Y. Miyairi, T.Aoki, S. Hirose, Y. Yamamoto, M. Makino, S. Miwa, and F. Abe, "Effect of cell shape on mass
transfer and pressure loss," SAE Internationals, 2003-01-0815, 2003.
M. Chen, J. Aleixo, S. Williams, and T. Leprince, "CFD modelling of 3-way catalytic converter with detailed
catalytic surface reaction mechanism," SAE Internationals, 2004.
S.H. Aminordin, "Computational fluid dynamics (CFD) analysis for a catalytic converter design,"
Thesis (M. Eng), Fakulti Kejuruteraan Mekanikal dan Pembuatan, Universiti Tun Hussein Onn
Malaysia, 2008.
D. Sebayang, P. Untoro, A.R. Hamimah, C.T. Lim, and M.I.S. Azizan, "The application of natural zeolite to
reduce harmful gases from exhaust system," 5th International Materials Technology Conference and
Exhibition, 2006, Malaysia: Institute of Materials Malaysia (IMM).
D. Sebayang, S.H Amirnordin, P. Untoro, and A.R. Hamimah, "Current status on the development of
catalytic converter project. 1st," Malaysian Technical University Colleges Annual Conference on
Engineering and Technology (MUCET), 2006.
A.R. Hamimah, K.F. Shahrudin, R.A. Ainun, and B. Hatijah, "Development of SiC-zeolite Porous ceramic.
Conference on applied sciences, 2006, Malaysia: UiTM.
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Daftar Pustaka

B.L. Lester, "Implementing technology-forcing policies: "The 1970 clean air act amendments and the introduction of
advanced automotive emissions control in the United States," Technological Forecasting and Social Change, vol. 72,
2005, pp. 761-778.
V.T. Martyn, "Roles of catalytic oxidation in control of vehicle exhaust emissions," Catalysis Today, vol. 117, 2006, pp.
407-418.
T. Shamim, and H. Shen, "Effect of geometric parameters on the performance of automotive catalytic converters,"
International Journal of Science and Technology, vol. 14, 2003, pp. 15-22.
R.M. Heck, and R.J. Farrauto, "Environmental catalysis into the 21 st century," Catalysis Today, vol. 55, 2000, pp. 179187.
M. Valentini, G. Groppi, C. Cristiani, M. Levi, E. Tronconi, and P. Forzatti. "The deposition of -Al 2O3 layers on ceramic
and metallic supports for the preparation of structured catalysts," Catalysis Today, vol. 69, 2001, pp. 307-314.
D. Betta et al. at R.E.Hayes and S.T. Kolaczkowski. Introduction to Catalytic Combustion. Amsterdam: Gordon and
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washcoat on FeCrAl," Surface & Coating Technology, vol.190, 2005, pp. 434-439.
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supported Cu-Pt bimetals as a Catalyst," SAE International, 2002-01-2147, 2002
Higashiyama,K., Nagayama,T., Nagano,M., Nakagawa,S., Tominaga,S., Murakami,K. and Hamada,I, "A catalyzed
hydrocarbon trap using metal-impregnated zeolite for SULEV systems," SAE International, 2003-01-0815, 2003.
D. Sebayang, P. Untoro, Y. Putrasari, Y.H. Soon, M.Hashim, and M. Ghomma, Influence of difference deposition
technique of nickel on FeCrAl metallic monolith," Malaysian Metallurgical Conference, 2009.
R.A. Searles, "Contribution of automotive catalytic converters," in Material Aspects in Automotive Catalytic Converters,
H. Bode, Ed. Germany: Wiley-VCH, 2002, pp. 3-16.
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Bode, Ed. Germany: Wiley-VCH, 2002, pp. 19-30.

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Daftar Pustaka

S.H. Aminordin, "Computational fluid dynamics (CFD) analysis for a catalytic converter design,"
Thesis (M. Eng), Fakulti Kejuruteraan Mekanikal dan Pembuatan, Universiti Tun Hussein Onn
Malaysia, 2008.
D. Sebayang, P. Untoro, A.R. Hamimah, C.T. Lim, and M.I.S. Azizan, "The application of natural zeolite to
reduce harmful gases from exhaust system," 5th International Materials Technology Conference and
Exhibition, 2006, Malaysia: Institute of Materials Malaysia (IMM).
D. Sebayang, S.H Amirnordin, P. Untoro, and A.R. Hamimah, "Current status on the development of
catalytic converter project. 1st," Malaysian Technical University Colleges Annual Conference on
Engineering and Technology (MUCET), 2006.
A.R. Hamimah, K.F. Shahrudin, R.A. Ainun, and B. Hatijah, "Development of SiC-zeolite Porous ceramic.
Conference on applied sciences, 2006, Malaysia: UiTM.
A.R. Hamimah, R.A. Ainun, B. Hatijah, and F.S. Khairul, "Influence of additive and sintering temperature
on porous ceramic properties," International Conference on Solid State Science and Technology, 2006,
Malaysia: KUSTEM.
I. Garrn, C. Reetz, N. Brandes, L.W. Kroh and H. Schubert, "Journal of the European Ceramic Society," vol.
24, 2004, pp. 579-587.
A.R. Hamimah, and C.G. Yap, "Preparation of ceramic foam by simple casting process," PSU-UNS
International Conference on Engineering and Environment (ICEE-2007), 2007.
R. M. Heck, R.J. Farrauto, and S.T. Gulati, Catalytic Air Pollution Control Comercial Technology 2nd ed,
New York: John Wiley & Sons, Inc, 2002, pp. 79-80.
US Patent, "NiO Catalyst Configuration, Methods for Making NOx Adsorbers, and Methods for Reducing
Emissions," No. US6,930,073B2., Aug. 16, 2005.
ThyssenKrupp VDM, Aluchrom Yhf, Material Data Sheet No. 4049, March 2008 Edition, Germany.
W.J. Quadakkers, and L. Singheiser, Materials Science Forum, vol. 77, 2001, pp. 369-372.
D. Naumenko, Effect of Metallurgical Chemistry and Service Condition on the Oxidation Limited Life
Time of FeCrAl-based Components, PhD Thesis, RWTH Aachen, 2001.
P. Untoro, M. Dani, H.-J. Klaar, J. Mayer, D. Naumenko, J.C. Kuo, and W.J. Quadakkers, "The effect of trace
amounts of Mg in fecral alloys on the microstructure of the protective alumina surface scales",
Proceeding of MACC, 2001,pp. 271-277.
M. F. Hassan, D. Sebayang P. Untoro, "Conceptual design of a spiral catalytic support", International
Conference on Mechanical & Manufacturing Engineering (ICME 2008), 2008.
M. F. Hasssan, D. Sebayang , P. Untoro, "Apparatus for producing a spiral shape of corrugated sheet
metal for substrate of catalytic converter", ICAME 09, Malaysia, 2009.
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