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What is a catalytic converter?

A catalytic converter (colloquially, "cat" or "catcon") is a device used to reduce the toxicity of emissions from an internal combustion engine. First widely introduced on series-production automobiles in the US market for the 1975 model year to comply with tightening EPA regulations on auto exhaust, catalytic converters are still most commonly used in motor vehicle exhaust systems. Catalytic converters are also used on generator sets, forklifts, mining equipment, trucks, buses, trains, and other engine-equipped machines. A catalytic converter provides an environment for a chemical reaction wherein toxic combustion by-products are converted to less-toxic substances.

What does it consist of?

1. The core, or substrate. In modern catalytic converters, this is most often a ceramic honeycomb, however stainless steel foil honeycombs are also used. The purpose of the core is to "support the catalyst" and therefore it is often called a "catalyst support". The ceramic substrate was invented by Rodney Bagley, Irwin Lachman and Ronald Lewis at Corning Glass for which they were inducted into the National Inventors Hall of Fame in 2002.

2. The wash coat. In an effort to make converters more efficient, a wash coat is utilized, most often a mixture of silicon and aluminium. The wash coat, when added to the core, forms a rough, irregular surface which has a far greater surface area than the flat core surfaces, which is desirable to give the converter core a larger surface area, and therefore more places for active precious metal sites. The catalyst is added to the wash coat (in suspension) before application to the core.

3. The catalyst itself is most often a precious metal. Platinum is the most active catalyst and is widely used. However, it is not suitable for all applications because of unwanted additional reactions and/or cost. Palladium and rhodium are two other precious metals that are used. Platinum and rhodium are used as a reduction catalyst, while platinum and palladium are used as an oxidization catalyst. Cerium, iron, manganese and nickel are also used, though each has its own limitations. Nickel is not legal for use in the European Union (due to nickel hydrate formation). While copper can be used, its use is illegal in North America due to the formation of dioxin.

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