Design and evaluation of a metallic gasoline particulate filter made of sintered metal fiber media

• Metallic fibrous material was selected as filter media to design a gasoline particulate filter (GPF) for gasoline engine after-treatment application. • Based on single fiber efficiency theory, a design procedure was developed to optimize the characteristics of metal fiber media (fiber size, porosity, and thickness) and the GPF cartridge (total media area). • Two GPF prototype units with different media surface areas were designed according to the application constraints and the material availability. Integrated mass collection efficiency of greater than 78% is found for both FTP-75 and US06 drive cycle, with an average backpressure less than 1 kPa over US06 drive cycle, on a 2.0 liter GDI engine passenger car. • PM removal efficiencies measured under engine dynamometer at constant exhaust temperature and flowrate agree well with model predictions. • Engine dyno data and CFD results indicate dominating contribution of inertia pressure loss at high Reynolds number, which needs to be reduced in future designs.