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Testing was performed on Corning's Generation 3 Electrically Heated Catalyst (EHC) to determine product reliability and durability. A number of functional measurements was performed before and after all electrical, thermal/mechanical and environmental tests. EHCs were also successfully tested on vehicles for 100,000 miles. The results of all tests were favorable and indicated that the new design meets or exceeds requirements.

Extruded metal honeycombs are used as electrically heated catalysts (EHCs). The durability requirements of this application make demands on high surface area, thin cross-section metal honeycombs. Significant durability improvements over previous extruded metal honeycomb EHCs have been achieved by material and package design changes. The product redesign was supported by finite element models and extensive testing. The redesigned EHC has passed severe laboratory and field testing. The tests include electrical cycling to 1000°C/1600 cycles, hot vibration to 60g/900°C and demanding on-vehicle exposure. Excellent durability of the extruded metal honeycomb has been demonstrated.