It is not known for certain who first awarded the car with a muffler, but it is generally believed that it was after all the Panar-Levassor company. These guys were the first to lose their nerves and they decided to adapt their car to society. To ensure that conservative citizens do not interfere with the development of the car, several attempts have been made to reduce the noise level emitted by the engine. As a result, instead of cutting the pipe, a whole system was screwed to the motor, which was called an acoustic filter. It was in 1893. So society won the first victory over the car, and the car received another system - an acoustic filter, or silencer.

A car muffler is an integral part of a car.

Breakdowns, burnouts and punctures

For too long a car muffler could not remain in an embryonic state. It grew and developed along with the car, and the first more or less human muffler appeared already in 1917, at least the patent for its invention dates back to the year of the revolution. Along with the technical improvement, the exhaust system also received new problems - the pipes burned out like paper, because the steel did not correspond to the working conditions and simply burned out in a short time.

The consequences of a burned-out car filter.

The manufacturers have not gone far since then, and the muffler has all the same problems as a hundred years ago. Only to them were added problems with catalysts, lambda probes and other new devices. Structurally, the muffler is quite simple - the exhaust manifold, front pipe, corrugation, catalytic converter, resonator and muffler itself. And a pair of pipes of the calculated diameter. That's the whole construction. But it works in inhuman conditions, which affect primarily the service life of the system. Even the most sophisticated and expensive premium cars with stainless and aluminized steel mufflers last no more than 10 years.
Mufflers supplied for replacement, aftermarket position, last two to three years, and suspiciously cheap mufflers for expensive cars last a year or two at most. Depressurization, breakdowns, burnouts, chemical corrosion, huge operating temperatures and incorrect installation are the main technological punctures in the exhaust system.

Photo of the structure of the car filter.

Exhaust system working conditions

Most of all goes to the exhaust manifold. The main heat load in the exhaust system falls on it. The manifold is smelted from refractory cast iron, as it is the only material available that can withstand operating temperatures up to 1300 ° C. The intake pipe receives a temperature of up to 1100 degrees, the catalyst operates at a temperature of about 1000. Further along the system, the operating temperature drops, but the chemical and mechanical load increases. But the resonator and its pipeline operate at temperatures up to 900 ° C, and the coolest in the system is the muffler. From the inside, it warms up to 300 degrees.

Exhaust manifold ZAZ Sens.

Temperature isn't the exhaust system's only enemy. Almost a great danger for each of the elements is chemistry, which is abundantly scattered along city roads. The main ingredient in road deicing, sodium chloride, is harmful even to stainless steel. It undergoes cracking after 5 years of active winter operation... Aluminized steels die much earlier, and low-alloy conventional steel collapses in a few winter seasons... If to this set we also add vibration load, mechanical damage, then the working conditions of the exhaust system will not be envied.

Repair or replacement

Even a bad substitute is better good repairbut not everyone can afford to change the exhaust system every year. It is possible to replace individual system components with low-cost mild steel parts, but in this case the price of the part and the price of repair must be correlated. In addition, not all manufacturers can guarantee full compliance of the replacement element with the original one in terms of configuration and attachment points. Bending angles of pipes, distortions in different planes, flange and diametrical landing dimensions can easily differ, so it is worth checking them before buying.

Video tutorial on replacing the outer shell of the muffler:

When deciding on a replacement, it is better to look after the products of proven brands that produce kits not only for foreign cars, but also for VAZs - Walker, Bosal, Rosi, Tesh. Quality Turkish and Polish spare parts also began to appear. The price of the finished part is influenced not only by the brand, but also by the material - a running meter of a system made of ordinary steel will cost about 350 rubles, and stainless steel can cost twice as much. For example, a new muffler for an old IGL Passat will cost 1,460 rubles.

Images of the muffler for the Passat B3.

Muffler sealant and other auto chemicals

If we face the truth, then worthy alternative there is no replacement of a burnt or burst part. There are a number of temporary measures that will prolong the life of a resonator or muffler. Even the highest quality welding and the neat seam placed on a dilapidated pipe will lead nowhere. Replacement is inevitable, like demobilization from a conscript. We will not consider welding today, it is a too voluminous and broad topic, but we will touch on the role of automotive chemistry and try to determine how expedient it is to invest money in foreign chemical industry.

Heat-resistant sealants allow you to repair only external problems in the auto muffler.

All auto chemicals intended for the repair and maintenance of the muffler are divided into three groups - assembly sealants for pipes, putties that can withstand high temperatures and bandage tapes to eliminate through damage to pipes and mufflers. To begin with, any chemotherapy only works on external surfaces. Damage to the internal organs of resonators and mufflers cannot be treated. Only when fully unpacked. Previously, such operations were carried out regularly, but now there is no shortage in resonators and mufflers, so few people will spend a lot of time repacking a damaged muffler.

Bandage tapes are used for through burnout or decay of elements of the round exhaust system. They can eliminate burnout, but such a patch will last a year at most. Many tapes have a high temperature adhesive for easy installation. Some of them can be planted on the muffler sealant. There are many types of such bandage tapes, for example, DONE DEAL DD6789 tape. It is made of fiberglass and impregnated with a solution of liquid sodium silicate. The impregnation also includes some modifiers that harden at the temperatures of the exhaust system. Cleared area exhaust pipe it is simply wrapped with such a tape at normal temperature, and after 40 minutes after wrapping, the ceramic jacket hardens completely. The ceramic bandage can be used at a working temperature of about 700 ° C, after hardening it is sanded and can be painted with heat-resistant paint. Reviews suggest that the thing is quite convenient, but it stinks terribly for a long time.

Photo of bandage tape for exhaust system.

A heat-resistant sealant is a more functional thing and is used not only and not so much for covering up holes, but for sealing thermally loaded joints of the exhaust system. It can be of great help in cases where it is not possible to disassemble the connection, if the assembly was set on a sealant during assembly. Pipes and clamps do not stick to each other, and good sealants allow you to create fairly reliable and tight connections. The price of sealants does not exceed 300-400 rubles for a 200-gram tube. To seal all the joints of the system, it will be enough to buy one tube of Abro sealant, and there will also be left for repair work. As the instructions say, it is simply applied to the cleaned surface. After application, the engine is started for 10-15 minutes, after which the composition hardens.

Before use, it is necessary to stand for a few more hours for complete solidification. Of course, sealants and bandages are not suitable for a full repair of a muffler, but they can save the situation for a year and a half, depending on the state of the exhaust system.

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CHEMICAL OUTLET

This year, the car muffler will celebrate the 113th anniversary of its birth. In 1894, the Panar-Levassor brand car was first equipped with such a detail as a silencer exhaust gases.

And it was definitely with technical point of a very progressive, and from a philosophical - an extremely humane step. Following the firm "Panar-Levassor" and other manufacturers of "horseless petrol carriages" hastened to complete their products with the appropriate device. But who remembers the name these days car brand Panar-Levassor? Units, and meanwhile the first petrol carthat crossed the border of the Russian Empire in the same 1894, was the car of the company "Panar-Levassor", and to the question "What is an automobile muffler?" any student will give you the answer. These days, depending on the model of a particular car, their exhaust systems can differ significantly from each other. But schematically, a modern car muffler can be represented as follows: an exhaust manifold, a front pipe, a catalyst, a resonator, a muffler, inlet and outlet pipes.

The exhaust manifold, the most heat-loaded part in the exhaust system of cars, is made of high-temperature cast iron, as a rule, damage to the intake manifold is caused by mechanical stress on it (for example, rolled studs). The operating temperature of the exhaust manifold can reach + 1300 ° C.

The intake pipe is attached to the exhaust manifold and also operates at high temperatures, the value of which sometimes reaches + 1100 ° C.

The exhaust gas catalytic converter is attached behind the front pipe. When the catalyst is operating, its honeycomb can heat up to + 1050 ° C.

The range of internal operating temperatures of the resonator installed after the catalyst can range from + 700 ° to +1000 ° C.

The rear muffler is the least thermally loaded part in the exhaust system; inside it, the operating temperature does not exceed +350 ° C.

At the same time, the temperature on the surface of various parts of the exhaust system is somewhat lower, the readings of which largely depend on design features each, separately taken, exhaust tract.

For the manufacture of parts of exhaust systems, ordinary or aluminized steel is used, less often stainless steel. Due to their longest lifespan, stainless steel exhaust systems are preferred by most car manufacturers. However, stainless steel is also susceptible to corrosion, namely stress corrosion cracking. The tendency to stress corrosion cracking is also determined by the composition of the corrosive environment. For stainless steels, the onset of the cracking process is caused by the presence of chlorides and alkali in the corrosive environment. It should be remembered that the most common anti-icing agent today is the composition of sodium chloride and calcium chloride. And yet, even under these conditions, the minimum service life of stainless steel exhaust systems can be five or even more years.

Exhaust systems made of aluminized steel are next in terms of lifespan. Minimum term the service of such systems is 3-4 years.

Exhaust systems welded from ordinary (unalloyed) steel rarely step over one and a half to two years of guaranteed operation.

Accordingly, the price of such systems increases in proportion to their declared service life.

The reasons for the destruction of the exhaust system elements can be very different, including the structural features of a particular exhaust system (the exposure of its individual components to mechanical stress, deformation, stone blows, abrasion, vibration, etc.), unfavorable climatic conditions (for example, the sea climate), the intensity of vehicle operation.

However, according to the conclusion of experts, they call the internal corrosion of metals as the main reason for the gradual destruction of parts of the exhaust system, which implies the chemical and electrochemical processes of its development.

The chemical type of corrosion is characterized by the entry of the metal into direct chemical interaction with environmental components. Chemical corrosion occurs in gas environments at high temperatures, for the exhaust tract car engine the gaseous form of the development of chemical corrosion is characteristic. Compounds of sulfur, chlorine, nitrogen, as well as oxygen and its compounds are used as aggressive components of the gaseous medium.

The active process of corrosion is promoted by a decrease in protective properties films that are formed from corrosion products and, in turn, prevent direct contact of aggressive components with metal. An increase in temperature leads to a decrease in the protective properties of such films, as well as the ingress of chemically active compounds into the intake tract, which are formed during the combustion of liquid fuel. An increase in the pressure and speed of movement of the gas medium also leads to an acceleration of the flow of the corrosion process.

And yet, even under the most favorable circumstances for its development, the rate of chemical corrosion will always be inferior to the rate of the electrochemical corrosion process. The main muffler housings located at the very end of the exhaust system are most susceptible to this form of corrosion.

A necessary condition for the occurrence of electrochemical corrosion of a metal is the presence on its surface of an electrolyte (aqueous solution of salts, acids, alkalis) capable of conducting an electric current. When the electrolyte contacts the surface of an essentially heterogeneous metal (the only exception to this rule is absolutely pure iron, which contains no more than a tenth of a percent of various impurities), many microgalvanic pairs are immediately formed on the metal surface, the work of which leads to the destruction of the metal.

When operating a car in a modern city, frequent short trips on, as a rule, not heated to the end of the car or many hours of languishing in "traffic jams" lead to the fact that the rear part of the muffler is not able to properly heat up and dry out, and as a result, in its body more and more water gradually accumulates. In addition, the process of corrosion of the main muffler is stimulated by the accumulation of a large amount of residues of incompletely burnt fuel in its atmosphere, entering into an oxidative reaction with the moisture accumulated in the muffler housing, it turns the latter into a powerful electrolyte. Therefore, unlike fish, the exhaust system begins to rot from the tail. To some extent, special drainage holes made in the lower part of the main muffler body help to correct this situation, through which water that has got inside the muffler body is drained.

From the outside, the exhaust tract literally "on its own skin" is able to feel all the "delights" of those roads, "... that we get." Here he is met by dust, and sand, and fine gravel, and a cold shower during the rain, and from time to time, hard encounters of one of its parts with a curbstone occur. At the same time, do not forget about such corrosive areas of the exhaust tract as its welds. By its characteristic type of damage - such corrosion as if with a knife cuts metal along the weld - it is called "knife". Also, the presence of rolled and seaming joints, protrusions, amplifiers, etc., on its parts, those places where the accumulation of dirt and moisture becomes possible - a kind of vanguard of corrosion, affects the corrosion protection of the exhaust system not in the best way.

Repair of mufflers can be accompanied by replacing the burnt / rusted part of the muffler with a new one, carrying out welding and restoration work. Or you can use special repair compounds that are offered in special stores in the form of various bandages, patches, putties, etc., which allow you to independently repair minor damage to the exhaust system, taking into account the thermal loads characteristic of each of its sections.

Over the past few years, the number of offers of such "repair kits" in our market has increased significantly. At the same time, presumably, the quality of such repair compositions has also improved, based on the fact that today it is produced, including those companies in high quality products of which we have more than once been able to see for ourselves

CONSUMER ANALYSIS The composition of the adhesive is used to seal small holes and cracks in automotive exhaust systems. The preparation includes in its composition: inorganic binders, fiberglass, a complex of special additives and water, does not contain asbestos and solvents. When the engine is idling, the adhesive hardens within the first 10 minutes. After final hardening, the glue copes well with all kinds of thermal and mechanical stress.

CRC "Assembly Paste"

CONSUMER ANALYSIS Mounting paste is used for assembling hose and flange connections in automotive and industrial exhaust (outlet) connections, has good sealing and lubricating properties, which greatly facilitates the work of assembling / disassembling exhaust (outlet) connections. The water-based heat-resistant assembly paste contains stable inorganic fillers and binders. The product does not contain asbestos and solvents. When heated, the paste composition swells and hardens quickly. After hardening, the assembly paste becomes resistant to thermal and mechanical stress.

CONSUMER ANALYSIS The kit is intended for sealing holes and cracks of various sizes in the exhaust system of a car. The bandage tape consists of epoxy impregnated fiberglass. The bandage is used to eliminate through holes and cracks formed on the surface of the elements automotive system exhaust gas release. The drug does not contain asbestos, it can withstand heat loads up to + 400 ° С. The repair kit includes: a bandage tape (1.5 m), a piece of wire to fix the bandage tape in the desired position until it solidifies, and a plate of heat-resistant foil, which helps to cover large areas of damage if necessary.

CONSUMER ANALYSIS The repair kit includes a bandage tape impregnated with a solution of liquid sodium silicate, and a metal wire that serves to temporarily fix the bandage tape in the desired position until it hardens. The repair kit is intended for the repair of catalytic converters housings and exhaust pipes of the muffler, the bandage tape can withstand temperature loads up to +1093 ° C. Does not contain asbestos, after final hardening, the repair coating becomes resistant to various mechanical loads

CONSUMER ANALYSIS High temperature sodium silicate formulation designed to repair minor damage to parts of the exhaust system such as muffler / resonator housing catalytic converter, as well as for sealing the docking points. The composition of the cement is gas-tight and can withstand thermal loads up to + 1093 ° C. In the normal operation of the car, the cement composition hardens within the next 24 hours after application.

CONSUMER ANALYSIS The bandage is designed for sealing small holes and cracks in the automobile exhaust system, easy to use, withstands temperature loads up to +426 ° C, gas tight. The bandage tape itself is made of fiberglass impregnated with epoxy. "Muffler band" is intended for repairing the exhaust pipes of the vehicle and the muffler / resonator housings. The final hardening of the shroud tape occurs when the vehicle's exhaust system is heated to the operating temperature.

CONSUMER ANALYSIS turret repair paste is intended for the repair of parts made of cast iron, steel and other metals. The composition of the paste is well suited for sealing holes / cracks in the intake / exhaust manifold housing, muffler receiver. The paste is based on a water-based binder with ceramic and stainless steel fillers. The final solidification of the composition occurs when the repaired part is heated to the operating temperature.

CONSUMER ANALYSIS High temperature ceramic tape for muffler repair (and pipes of any material). Repair tape-bandage DONE DEAL DD6789 is made of fiberglass impregnated with a solution of liquid sodium silicate, mixed with a complex of additives that make up the company's know-how, and is intended for repairing exhaust pipes, burnt mufflers, etc., operating at a temperature up to +650 ° С and pressure up to 20 atm. At a temperature of +25 ° C, after 30-40 minutes, the repaired section of the pipe is covered with a durable ceramic jacket. After final hardening, the repaired area can be sanded and painted with heat resistant paints.

CONSUMER ANALYSIS The VERSACHEM repair kit is intended for sealing holes, cracks and sealing welds on the body of car mufflers. The repair kit includes a bandage tape and a tube with a liquid activator. If it is necessary to cover a large area of \u200b\u200bdamage, you can use the material from which the tube body is made, with an activator. When conducting renovation works optimum temperature the exhaust system is approximately + 15-20 ° C. The engine can be started only after thirty minutes after the end of the repair and restoration work. The final hardening of the repair band occurs within ten minutes when the engine is idling.

CONSUMER ANALYSIS The VERSACHEM "Muffler cast exhaust bandage" repair kit is designed to repair cracks in the catalyst housing, as well as repair small holes on the surface of the resonator and exhaust pipes. The basis of the repair kit is a bandage tape made of a material impregnated with a special heat-resistant compound, due to which its consumer qualities have noticeably improved in comparison with similar compounds with a fiberglass base. When carrying out repairs, the optimum temperature of the exhaust system is approximately + 15-20 ° C. At the end of the repair work, the bandage needs 10-12 hours to dry, in order to accelerate the drying / hardening process of the bandage tape, you can start the engine and let it idle for 10 minutes.

CONSUMER ANALYSIS The VERSACHEM "Muffler-cast" bandage tape is intended for repairing small holes and rust-damaged areas on the surfaces of catalysts, resonators, intake and exhaust pipes. The tape is made of a special refractory material, due to which, in terms of its consumer properties, it surpasses similar products made on the basis of fiberglass, incl. well resists the process of chemical corrosion At the end of the repair work, the bandage dries for 10-12 hours; to speed up the drying / hardening of the bandage tape, you can start the engine and let it idle for 10 minutes.

CONSUMER ANALYSIS VERSACHEM muffler cold weld compound "Muffler weld" is intended for repairing minor damage to automotive exhaust system components such as resonator, main muffler and exhaust pipes. "Cold welding" has excellent adhesion to various metal surfaces, including surfaces with traces of rust, its composition is well resistant to the aggressive environment of hot exhaust gases. When carrying out repairs, the optimum temperature of the exhaust system is approximately + 15-20 ° C, finally, the product dries up 10-12 hours after application.

CONSUMER ANALYSIS High temperature, gas-tight paste for exhaust system seals. Prevents gas breakthroughs at the joints of the individual muffler components and the welding of the latter to each other. When conducting installation works the surfaces of the parts must be free of rust and different sorts pollution. After applying the LIAUI MOLY Auspuff-montage paste on the parts, for a better tightness of the joint, it is necessary to slightly "rub" their surfaces against each other. To improve the elasticity of the paste, it is allowed to wet the joints with water. The final curing of the assembly paste comes from heating the exhaust system when the engine is idling.

CONSUMER ANALYSIS LIQUI MOLY Auspuff-bandage gebreuchfertig kit is designed to seal large damages and cracks in the car exhaust system, absolutely gas tight. The kit consists of a 100 cm fiberglass reinforcement tape and a pair of gloves. When carrying out repair and restoration work, the bandage tape is tightly applied around the damaged area with the aluminum side outward. When the exhaust system heats up, the inner layer applied to the band hardens and seals the hole.

CONSUMER ANALYSIS LIQUI MOLY KERAMIK-PASTE, a synthetic, high-temperature, metal-free paste prevents sticking, sticking, rusting of threads, splines, pins, bolts, spindles and others, incl. non-metallic materials operating in high temperature and corrosive environments (exhaust system, vehicle braking system). It is used as a lubricant for processing highly loaded sliding surfaces operating at low sliding speeds and oscillatory movements. Application temperature range from -30 ° С to +1400 ° С, the composition of LIQUI MOLY KERAMIK-PASTE paste is resistant to hot and cold water, as well as to the action of acids and alkalis.

MOTIP Heat-resistant paint

CONSUMER ANALYSIS Special heat-resistant acrylic paint MOTIP, designed for surface treatment of parts exposed to high temperatures, such as elements of a car engine, exhaust systems, radiators, etc. Permanent heat resistance up to 650 ° С, short-term - up to 800 ° С. Red paint and heat-resistant colorless varnish are permanently heat-resistant up to 300 ° C. Color: anthracite / dark anthracite, black, silver, white, beige, gray, red.

Many of us always have a fear of the exhaust system. We all know that everything heats up because of the hot exhaust gases coming from the engine, as a result of which many people got burns from it. Owners of motorcycles in which the exhaust pipes are located in close proximity to the legs are especially aware of this. But how much does the exhaust system actually get hot? Are all elements of the system evenly heated? See a detailed video about this on the example of the S2000 car, which was filmed using a special thermal imager.

It . The author of these videos this time made a video about the operation of the car's exhaust system. The video was filmed from the very start of the engine. Then the author, after a good blow-off, showed us how all the components of the exhaust system heat up.

An excellent video that shows us in detail the system for removing hot gases from the engine combustion chamber.

Note that the video is overlaid with data from the various components of the exhaust system (top left corner). As you can see, for example, the muffler, in spite of fears, actually does not heat up very much. Although the individual components of the exhaust system are really very hot.

It is worth noting, however, that the video was filmed while the car was idling. What will the exhaust system look like through the eyes of a thermal camera while the car is moving? It would also be interesting to see. We hope that the author of the video will answer this question soon.

For those who have not seen other videos filmed with the thermal commer, here is a list.

During the operation of the engine, the combustible fuel in the chambers turns into energy and exhaust gases that need to be removed, since it is necessary to free up space for the next fuel mixture. The piston is set in motion by the released energy, while it also serves as a force for squeezing exhaust gases out of the system. For this process to take place smoothly, it is important to create a rarefied environment on the other side.

For this purpose, pipes for exhaust systems are used in the design of a car, often, for the connection of which, a corrugation is used.

Why is thin air in the system so important? It is due to this state of air that the chamber is quickly freed from gases. It turns out something like a vacuum cleaner effect. Therefore, the chamber becomes as free as possible to receive a new portion. fuel mixture... How is sparsity achieved in the system? This effect is formed as a result of the action of the inertial forces of gases. After the emission of exhaust gases, the pressure rises, and then a rarefied atmosphere is created.

Additional bends in the system, as well as all kinds of elements or malfunctions, such as an incorrectly mounted corrugation, can prevent the process of gases from leaving the cylinder. As a result, an incomplete portion of the fuel mixture enters the chamber, and the overall engine power is significantly reduced. To avoid similar problems, often use direct-flow exhaust systems, sometimes with an increased pipe diameter. This allows the waste gases to leave the system unhindered.

The straight-through system consists of a manifold that can branch out to the number of cylinders in the engine. The next element is a catalyst, which provides partial purification of gases.

After that, the exhaust is directed to the resonator, where the gas velocity is reduced and the exhaust noise is initially muffled. A muffler is then located in the path of the system, which minimizes exhaust noise. This part can contain sensors and a soot filter. Each of the nodes can connect a corrugation to another.

If we take a standard exhaust system as an example, then, as a rule, it has several places that make it difficult for the rapid and smooth movement of gases in the system. Is absent particulate filter, and the resonator in such system goes with reduced resistance. The most vulnerable spot in such a system is the exhaust manifold. It needs to be changed first.

The design of the collector depends on its length. For example, a short one would have a 4-1 construction. This means that the four branches will converge into one pipe. If this is a long section, then most likely it has a 4-2-1 design. According to this scheme, four taps are connected in pairs, that is, into two pipes, and then this pair into one pipe. The shorter manifold design is more suitable for powerful cars and those who love speed, as it adds power at 6,000 thousand rpm. The second option is more suitable for urban traffic. It should be remembered that changing the configuration of the exhaust system leads to the need to adjust the fuel supply system of the car, and the corrugation will help to connect the sections.

As for the resonator, it must be installed in that section of the system where the gas pressure decreases. This is necessary to increase engine power.

In this section, the gas velocity is pumped up by the reflector, the volume of the purge of the engine chambers increases, which leads to an increase in the total power due to an increase in revolutions. And in order to reduce the effect on reducing the rarefaction of air in the system, the muffler should be installed as far as possible from the resonator. A special corrugation is suitable for their fastening.

We can say that in a standard system, a wide piece of pipe at the end of the section plays the role of damping the sound of the exhaust gas outlet up to a level of 100 dB. But if you replace the tip with type A, then the engine power increases significantly. At the same time, the volume of the exhaust also increases to unacceptable standards within the city, 120 dB.

During the operation of the car, any part is subject to wear. The body and suspension elements will last longer as they are manufactured to withstand harsh environments and conditions. There are units and parts that are subject to faster wear and tear and obsolescence. These include brake pads (they wear out with direct use), gears in a variable transmission box that are subject to heavy loads, corrugation, etc. What about the exhaust system?

This unit is also susceptible to mechanical damage from the same stones on the road. But it is more damaged by the aggressive environment of chemicals contained in exhaust gases and high temperatures. For example, the collector temperature during operation reaches 1300 degrees. To avoid melting, it is made from high temperature cast iron. At the junction of the collector and the pipe, which connects the corrugation, the temperature can reach 1100 degrees, and the catalyst can reach a temperature of 1050, etc.

However, such temperatures are reached inside the system itself, and not outside, so the situation there is a little easier. But at the same time, the external part is affected by the difference in ambient temperatures, as well as all kinds of chemical compounds, which remove ice on the roadway.

Thus, the service life of the exhaust system is about 3-4 years, and if its body is not made of alloy steel, then even less.

The main load falls on the junctions of nodes. Especially from various materials. In this case, corrugation is often used. To avoid leakage of exhaust gases and leakage, use an exhaust system sealant that can withstand up to 1090 degrees.

A faulty muffler is very easy to spot. In this case, a visual inspection is not even necessary. A muffler requiring repair can be heard from a mile away. A loud unpleasant sound can make even the most seasoned person turn around.

The muffler, which appeared at the dawn of the automotive industry, made it possible to bring peace to the city quarters of cities, which were often disturbed by the roar of the engines of the first vehicles. The loud sneezing sound of imperfect motors pressed on the eardrums and frightened the local kids.

The approach of a car at the end of the 19th century could be heard a block away. The use of a muffler solved this sound problem. Cars began to drive quieter without disturbing the sleep and peace of city dwellers.

The car muffler is an integral part of the exhaust gas evacuation system generated during engine operation. Its main task is to forcibly suppress the noise that occurs when the exhaust gases of the combustion fuel are removed.

The first mufflers were of a primitive design, relatively weak, suppressing noise. As a result of the high exhaust gas temperatures, the low-quality element material became unusable and began to resonate during engine operation.

A high-quality modern muffler is able to effectively suppress noise, transforming them into a pleasant "rumbling" from the exhaust pipe. The material used to manufacture the product has a high level of shock resistance temperature regime and corrosion.

The design and device of the muffler of almost all car models from different manufacturers do not differ from each other. It is simple yet effective.

It is she who receives the first hot exhaust gases from the engine combustion chamber. Very often, their temperature can reach 1000 degrees.

That is why the intake pipe is made of refractory materials that are resistant to high temperatures. Generally, car manufacturers use cast iron and steel alloy

Its task is to neutralize maximum number harmful substances in exhaust gases to less hazardous elements. The work of the catalyst is aimed at minimizing damage to the environment into which the exhaust gases enter

3. Front muffler

It is also called a resonator, as it absorbs the sounds made by the exhaust gases passing through it. Among other things, it minimizes vibration by reducing the rate of passage of gases.

It is the front muffler that reduces the noise of the vehicle, taking the brunt of the blows coming from high speed hot gases from combustible fuel

It completely reduces the noise of the machine and removes exhaust gases into the environment. Their temperature is reduced to the minimum safe level.

The operation of the muffler and the entire exhaust system is associated with high temperatures. All this leads to damage to the muffler surface over time.

Every driver, without exception, heard how the damaged muffler works. The noise of the car in motion, especially in low gears, increases significantly. All this creates a certain discomfort for the driver and other road users.

The weak link of any muffler is, of course, the weld. With intensive use of the machine, it begins to thin out under the influence of high temperature.

Ultimately, the material burns out and begins to pass exhaust gases. Extraneous soundthat appears when the motor is running is one of the first signs of a problem.

Often, active use of the machine in winter leads to corrosive damage to the muffler surface. The processes of formation of foci of rust are accelerated when using a salt deicing mixture on the roads and temperature changes.

Almost every car in its lifetime has "seen" the replacement and repair of the muffler at least once during the period of operation.

The importance of the structural component of the exhaust system should not be understated. It is the muffler that is able to normalize the operation of the engine and a comfortable ride on the car.

Thank you for your attention, good luck on the road. Read, comment and ask questions. Subscribe to fresh and interesting articles on the site.

Exhaust system in turbocharged diesel engines ATD and AXR

The task of the exhaust system is to remove the exhaust gases and at the same time maintain the amount of harmful substances in the exhaust gases at a minimum level (operating mode of the catalytic converter). In addition, the exhaust system reduces combustion noise to a minimum.

The design of the exhaust system depends on the engine model. The parts of the exhaust system are screwed together or connected with clamping clamps and can be replaced separately.

Heat shields along the pipe path prevent strong heat radiation to the lower body parts. After dismantling, all self-locking nuts and gaskets must always be replaced. The retaining rings and rubber buffers are also replaceable.

Exhaust pipe system life

The exhaust pipe in your car is rated for 60,000 km. Of course, its service life also depends on the operating conditions of your vehicle. If you mainly drive short distances, there is much more condensation, soot, and corrosive acids inside the exhaust system than when traveling long distances with a well-heated engine.

• The exhaust pipe with the installed catalytic converter is less likely to be corroded than other components, because there combustion gases still flow out with a temperature of 800 to 1000 ° C.
• In the exhaust pipe and the end silencer, the exhaust gases significantly reduce their temperature; in the final muffler, their temperature is only 150–300 ° С. Therefore, the most water condensate appears in the final muffler. It mixes with combustion products, forming corrosive acids, causing perforating corrosion of the metal of the exhaust pipe from the inside out.
• The front parts of the exhaust system when driving long distances can suffer from thermal stress when hot metal is constantly exposed to cold showers during rain. Material may crack or break.
• Splashing water or salt water will corrode the outside. Hitting stones or hard ground, as well as vibrations resulting from defective or missing pipe hangers, will also shorten the life of the exhaust pipe.
• Avoid unfavorable conditions that can lead to high temperatures in the catalytic converter. The vehicle must not be parked in a location close to flammable materials.
• Applying additional anti-corrosion protection or anti-corrosion agents to the exhaust manifold and exhaust pipes, catalytic converters and heat shields will not prolong the life of the exhaust system. These substances can catch fire during travel.

Reducing the toxicity of exhaust gases

The fuel is mostly carbon and hydrogen. When burned, carbon combines with atmospheric oxygen to form carbon dioxide (CO2), hydrogen combines with oxygen (O2) to form water (h3O). For example, from 1 liter diesel fuel about 0.9 liters of water is formed, which, due to the heat of combustion, is invisibly removed through the exhaust system. In winter, after starting a cold engine, you can often see white puffs of exhaust. This is condensation water.

Even in a diesel engine, which operates in contrast to a gasoline engine with a large amount of air, poisonous substances are generated, albeit in a relatively smaller amount. Reducing emissions is essential for meeting stringent exhaust gas standards and for TDI diesel engines.

In order for the exhaust system to function flawlessly, it is imperative that only unleaded gasoline be filled into the tank. The catalytic converter fails due to the lead in leaded gasoline. Plus, you never need to drive until empty. fuel tank... Irregular fuel supply results in misfiring, allowing unburned fuel to enter the exhaust system. This can lead to overheating and damage to the catalytic converter.

Turbocharger ensures clean combustion

With a large amount of air in the combustion chamber, the fuel burns "clean". Exhaust gas constituents such as carbon monoxide and soot are generated in very small quantities. The turbocharger provides more intake air.

As a result, a surplus of air occurs during combustion with relatively small injected fuel quantities. This leads to a reduced amount of harmful substances in the exhaust. The turbocharger uses exhaust gases flowing at supersonic speed through the exhaust manifold as drive energy. The gases pass through the turbine housing where they accelerate the pump rotor to over 100,000 rpm. The rotor drives the compressor wheel by means of a shaft. It draws fresh air into the compressor housing and pushes it into the combustion chambers. Turbocharging reduces exhaust emissions and noise, while increasing power output and efficiency.

Secondary air for cold starting

Thanks to the secondary air system, an accelerated heating is achieved and due to this, an early readiness of the catalytic converter after starting a cold engine.

Principle: Due to excessive enrichment of the working mixture at the stage of starting a cold engine, the exhaust gases contain an increased proportion of unburned hydrocarbons. The secondary air injection in the catalytic converter improves the subsequent oxidation and thus reduces the emission of harmful substances. The released energy reduces the preparation time for the catalytic converter, thereby improving the quality of exhaust gases during the warm-up phase of the engine.

Function: The engine control unit controls a secondary pump for boosting secondary air via a relay. The air is supplied to the universal valves. In parallel, the secondary air boost valve is adjusted, which passes the reduced pressure to the universal valves for secondary air boost. As a result, each universal valve opens the way for secondary air to the exhaust ports in the cylinder head.

From the vacuum box, the pipeline goes through the return valve (to the inlet pipeline) to the secondary air boost valve. Fresh air flows from the air filter housing to the secondary air pump.

Exhaust gas warning light

If the engine control unit detects a malfunction, this is indicated by illuminating the exhaust gas warning light. The exhaust gas warning light can be flashing or continuous. In any case, you must contact a workshop to interrogate the fault memory.

If the light is on in an intermittent mode, then there is a defect, which in this state of movement can cause damage to the catalytic converter. In this case, you can only drive with reduced power. If the light is on continuously, it means that there is a malfunction that worsens the composition of the exhaust gases. It is necessary to read the information in the fault memory of the engine control unit and automatic transmission gear.

In gasoline and diesel engines, along with turbocharging and an exhaust gas recirculation system, catalytic converters ensure the purity of the exhaust gases. In gasoline engines these are regulated catalytic converters with lambda probes, in diesel engines they are unregulated catalytic oxidation converters. This catalytic converter converts carbon monoxide and hydrocarbons to carbon dioxide and water.

Sectional Adjustable Catalytic Converter:

This exhaust gas recirculation system reduces carbon monoxide. This system includes an exhaust gas recirculation valve, which, when the engine is warm, diverts some of the gases back into the combustion chamber. This lowers the combustion temperature and therefore the proportion of harmful substances in the exhaust.

The design of the catalytic oxidation converter: a cellular ceramic body 2 is placed in a stainless steel housing 1. It is covered with a layer of aluminum oxide 3, due to which its surface is increased 700 times. A noble metal, platinum 4, was sprayed onto this support layer as a catalyst.

Particulate matter emissions are characteristic of diesel engines. It is significantly higher than that of gasoline engines. The particles are mostly carbon (soot). The remainder consists of soot-related hydrocarbon compounds, fuel aerosols and lubricating oilsas well as sulfates, depending on the sulfur content of the fuel used.

Soot particles are chains of carbon particles with a very large specific surface, to which unburned or partially burnt hydrocarbons are attached. In most cases, these are aldehydes (with a large number of molecules) with an annoying odor. The resulting pollution, reduced visibility and odor are certainly harmful to the environment.

In addition to the odors attached to soot, it is assumed to have harmful effects on health. There is no documented evidence of this, but nevertheless, in the development of modern diesel engines, of course, the elimination of particulate matter is of paramount importance.

Exhaust gas recirculation

An opportunity to reduce the inevitable high temperatures in the combustion chambers of a diesel engine, responsible for the high proportion of carbon monoxide, is the intake of the exhaust gases. Exhaust gas recirculation can also reduce the amount of carbon monoxide in gasoline engines. For this, a part of the flow is separated from the engine exhaust gases by a system controlled by valves. The recirculation valve in the Polo has a tapered tappet shape, which allows a different cross-section of the opening with different valve lift. In this case, intermediate values \u200b\u200bare also possible. The quantity is metered and sent back to the intake manifold depending on the load on the engine.

Assessment of the potential of a diesel engine: with improved quality of fuel and lubricants and using the most modern technology, the requirements of EN 4 are achieved.

Of course, the exhaust gases cannot be burnt again, because they contain almost no combustion substances. However, this reduces the supply of fresh air for combustion, and this affects a decrease in temperature and, consequently, a decrease in the proportion of carbon monoxide.

The valve control depends on the characteristics of the engine control units. In a petrol engine, the self-diagnosis function of the Motronic ignition / injection system control unit J220 monitors the EGR control. On TDI engines, the EGR is adjusted by the control unit. direct injection diesel engine J248 via EGR valve N18 directly to the EGR valve.

In each case, the principle of operation is to divert as much exhaust gas as possible without disrupting the operation of the engine. The better this is done, the more the temperature in the combustion chambers decreases, which leads to a decrease in carbon monoxide emissions.

Due to the significantly different design of the intake and exhaust manifolds, the exhaust gas recirculation system in the 4-cylinder TDI engine with the letter designation AXR looks slightly different.

Exhaust gas recirculation in 3-cylinder petrol engines AWY and AZQ