Methods for depositing inorganic particles including titanium carbonitride on a metal substrate via chemical vapor deposition (CVD). In some embodiments, the CVD process may be supplied by two or more source gasses that react to form the inorganic particles. At least one of the sources gases includes a titanium source gas. And a source of carbon and nitrogen may be (a) a single source gas including a carbon and nitrogen source gas with a heat of formation energy that is less than 65.9 kilojoules per mole and/or (b) two source gases including a carbon source gas with a gas molecule having a carbon-nitrogen single bond and a nitrogen source gas. In some embodiments, the CVD process may be supplied by a source gas including a metalorganic compound to form the inorganic particles. In some embodiments, the CVD process may be supplied by an aluminum-containing metalorganic reducing agent.

A method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.

In a method of making a gaseous emissions treatment component, a ‘green’ ceramic mix is extruded through a die to form an extrusion having cells extending along the extrusion, the cells being bounded by walls dividing adjacent cells from one another. In concert with the extruding, metal is fed through the die with the extruded mix. A length of the extrusion and associated metal is then cut off and fired to form the component.

An extruder head for extruding a strand of building material for 3D printing of a structural part. The extruder head has an extruder nozzle with a discharge opening for discharging the strand of building material out of the extruder head in a discharge direction, a specification element designed to be variably adjustable for variably settably specifying at least a part of a strand cross section of the strand of building material being discharged, and a setting apparatus designed for variably setting the at least one specification element. The setting apparatus is designed and arranged such that the extruder head, in a first extent direction which differs from the discharge direction, extends below the discharge opening, in the case of a maximum opening height, by at most the maximum opening height, and/or, in at least one second extent direction differing from the discharge direction, extends to the side of the discharge opening, in the case of a maximum opening width, by at most the maximum opening width.

A plugged honeycomb structure includes intersecting porous walls extending in an axial direction between an inlet end and an outlet end of the honeycomb structure, the intersecting porous walls forming a matrix of repeating unit cells arranged in a repeating pattern. The repeating unit cells comprise: three or four channels, each channel formed by four walls, wherein the three or four channels comprise more inlet channels than outlet channels, at least one wall of an inlet channel or an outlet channel is intersected midwall by a wall, an area of an outlet channel is equal to or less than an area of any of the inlet channels, and continuous line segments extending along walls of at least three repeating unit cells. Other plugged honeycomb structures, plugged honeycomb bodies, honeycomb extrusion dies, and methods are disclosed.

A honeycomb structure (110) includes intersecting porous walls (106). Inlet channels (108i) and outlet channels (108o) are formed by the intersecting porous walls (106), wherein the inlet channels (108i) comprise inlet hydraulic diameters (HDi) and the outlet channels (108o) comprise outlet hydraulic diameters (HDo). The inlet channels (108i) comprise inlet corners (220i) with inlet corner radii (Ri) and the outlet channels (108o) comprise outlet corners (2200) with outlet corner radii (Ro). A centerpost (124) is defined by adjacent opposing inlet corners (220i) of two of the inlet channels (108i) and adjacent opposing outlet corners (2200) of two of the outlet channels (108o). A first diagonal length (D1) is a shortest distance between the opposing outlet corners (220o) of the two outlet channels (108o) and a second diagonal length (D2) is a shortest distance between the opposing inlet corners (220i) of the two inlet channels (108i). The honeycomb structure (110) has certain aspect ratios D1:D2 depending on hydraulic diameter ratios HDi:HDo.

A thin-walled honeycomb body (100) having a plurality of repeating cell structures (110) formed of intersecting porous thick walls (112V, 112H) and thin walls (114V, 114H). Each repeating cell structure (110) is bounded on its periphery by the thick walls (112V, 122H) of a first transverse thickness (Tk) and the thin walls (114V, 114H) have a second transverse thickness (Tt) that subdivides each repeating cell structure (110) into between 7 and 36 individual cells (108). In the thin-walled honeycomb body (100), the first transverse thickness (Tk) of the thick walls (112V, 112H) is less than or equal to 0.127 mm (0.005 inch) and the second transverse thickness (Tt) of the thin walls (114V, 114H) is less than or equal to 0.0635 mm (0.0025 inch), and Tk>Tt. Honeycomb extrusion dies and methods of manufacturing the thin-walled honeycomb body (100) having thick walls (112V, 112H) and thin walls (114V, 114H) are provided.

A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.

A system (100) and method to control rheology of ceramic pre-cursor batch during extrusion is described herein. An extrusion system (100) comprises an extruder (122) with an input port (144) configured to feed ceramic pre-cursor batch into a first section (120) of an extruder barrel and a discharge port configured to extrude a ceramic pre-cursor extrudate (172) out of the extruder barrel downstream of the input port (144). A liquid injector (210) is configured to inject liquid into the ceramic pre-cursor batch. A sensor (106) is configured to detect a rheology characteristic of the ceramic pre-cursor batch. A controller (108) is configured (i) to receive the rheology characteristic from the sensor (106), (ii) compare the rheology characteristic to a predetermined rheology value of the ceramic pre-cursor batch, and (iii) generate a command based on the comparison. A liquid regulator (110) is configured to receive the command and adjust liquid flow to the liquid injector (210) based on the command.

A skin-forming die includes an inlet face; an outlet face; one or more slots, each of the one or more slots comprising one or more slot inlets extending between the one or more slot inlets and the outlet face; a plurality of feedholes extending between the inlet face and the one or more slot inlets; and a central opening configured to receive a matrix die. Extrusion die apparatus and methods of manufacturing honeycomb bodies are also disclosed.