An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. A weld bead is applied to at least one of the edges of the diffusion surface alloyed metal sheet for edge protection or to join the edge of the diffusion surface alloyed metal sheet to another diffusion surface alloyed metal sheet. The weld bead includes a high chromium content filler metal to protect the weld bead and the primary metal substrate at the weld joint from corrosion.

An exhaust component for a motor vehicle with improved corrosion resistance, including an internal volume, an inlet for receiving exhaust gas, and an outlet for expelling exhaust gas. The exhaust component includes at least one wall that is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. The primary metal substrate of the diffusion surface alloyed metal sheet is a stainless steel containing at least 10 percent chromium. The secondary metal of the diffusion surface alloyed metal sheet is a metal alloy containing 20 to 35 percent chromium. As a result, the secondary metal of the diffusion surface alloyed metal sheet provides improved corrosion resistance to salt spray and urea.

An exhaust component for a motor vehicle with improved corrosion resistance, including a housing with outer walls that define an internal volume and one or more inner walls that divide the internal volume into an exhaust chamber and an interior chamber. The interior chamber is isolated from the exhaust chamber and the external environment. At least part of one outer wall or one inner wall is made of a diffusion surface alloyed metal sheet. The diffusion surface alloyed metal sheet comprises a secondary metal that is formed to a primary metal substrate by diffusion. The diffusion surface alloyed metal sheet includes edges that are oriented toward and exposed to the interior chamber. As a result, the primary metal substrate at the edges of the diffusion surface alloyed metal sheet is protected from exposure to corrosives such as salt spray in the external environment and urea in the exhaust chamber respectively.

A process for manufacturing an exhaust system, especially for an internal combustion engine of a vehicle, includes providing an exhaust gas-guiding component (26) with a wall (38) made of a metallic material and providing a sensor-mounting connector (22), to be fixed at the wall. The sensor-mounting connector includes a sensor-mounting area (28) to be positioned outside the exhaust gas-guiding component, and a connection area (34), which is to be positioned such that the connection area meshes with the wall. The connection area is pressed against an outer surface (40) of the wall of the exhaust gas-guiding component in a fastening area (39) of the wall, and at the same time rotated about a longitudinal axis (A) of the connector to penetrate into the material forming the wall and a connection in substance is established between the metallic material of the wall and the metallic material of the sensor-mounting connector.

An aftertreatment component includes an aftertreatment housing. The aftertreatment housing has a first surface positioned so as to be directly impinged by diesel exhaust fluid injected into the aftertreatment housing. The first surface is a polished surface.

A stainless steel that includes chromium and other alloying element as a plurality of alloying elements including: a base material layer including chromium of a specified chromium content necessary for forming a passive film or more; and a superficial layer including chromium at a lower chromium content than the chromium content contained in the base material layer, and the superficial layer including the other alloying elements at a same content of the other alloying element as the content of the other alloying element contained in the base material layer.

A feedthrough in a housing component that is subject to thermal loading for a functional assembly includes: an inner conductor; an outer conductor having a sleeve assigned to or formed on the outer conductor that retains or makes it possible to fasten the feedthrough to the housing component; and an electrically insulating component between the outer conductor and the inner conductor, the electrically insulating component retaining the inner conductor relative to the outer conductor in an electrically insulated fashion.

An exhaust silencer for a motor vehicle is provided. In one example, the silencer comprises a noise-reducing structure and a heat sink to transfer heat from exhaust gases to the exterior of the silencer, the heat sink comprising two regions of fins which define a plurality of flow channels through the heat sink, the flow channels directing the flow of exhaust through the silencer from an inlet passage to an outlet passage. In this way, a temperature of the exhaust is reduced, and the silencer and downstream components of an exhaust system may be constructed of materials of a lower thermal tolerance.

An exhaust gas aftertreatment system for a vehicle includes a cylindrical inner shell, a cylindrical outer shell, an inner end cap, a metal mounting member, and an outer end cap. The inner shell is configured to guide exhaust gas. The outer shell forms a first gap to the inner shell. The inner end cap encloses an open end of the outer shell. The inner end cap includes a first axially-extending lip. The inner end cap is fixed to the inner shell. The outer end cap is fixed to the inner end cap. The outer end cap includes a second axially-extending lip. The outer end cap and the inner end cap cooperate to encapsulate the mounting member. The first axially-extending lip is sandwiched between the outer shell and the second axially-extending lip.

A muffler system with a muffler in one aspect of the present disclosure includes an outer wall, and a first separator and a second separator that partition a muffling space. An attachment member is arranged on an outer surface of the outer wall, and a muffler pipe to communicate with the muffling space is arranged to pass through an attachment member hole in the attachment member. The outer surface of the outer wall includes a first area and a second area. The first area is located between a first end of the muffling space and the first separator, and the second area is located between a second end of the muffling space and the second separator. The attachment member is welded to the first and second areas of the outer surface of the outer wall.