

Grey cast iron has low tensile strength and elongation and therefore not exhibit enough toughness required to withstand the severe working conditions. Low allow steels were not selected because they tends to exhibits poor corrosion resistance when exposed to salt on the road surface and condensate from the exhaust system. Nickel-based superalloys and Nickel-chromium alloys possess suitable properties for this application, but were not considered due to their high densities and high cost. Similarly, low alloy steels, stainless steel, grey cast iron, Nickel-based superalloys, Nickel-chromium alloys were obtained in the material selection for downpipe silencer/ muffler box and tail pipe. Variety of materials including Nickel-based superalloys, stainless steel, Nickel-chromium alloys were obtained in the material selection route for exhaust manifold. Mass, cost, high temperature (>800 o C for exhaust manifold and >400 o C for downpipe silencer/ muffler box and tail pipe) and high corrosion resistance were used as basic criteria for the material selection. The functions of each component were discussed, highlighting how they function as part of the exhaust and Cambridge Engineering Software (CES) software was employed in the material selection process. CES EduPack enables the scientist, engineer or designer to make a sensible selection by judicious comparison of materials via the inspection of data sheets for each material and by graphing property relationships for a shortlist of materials.This report reviews the automotive exhaust system with respect to its in-service conditions and selection of suitable materials for exhaust manifold, downpipe silencer/ muffler box and tail pipe which comprises the exhaust system. The selection of natural materials is often driven by the requirement of a combination of properties, for example, thermal insulation, durability and price for construction applications. A better comparison of density and cost can be made by using CES EduPack's advanced plotting facility. It is intended as a teaching medium for students in the fields of engineering, design, science and sustainable development, but it is also applicable to researchers, industrial scientists and engineers who are able to select engineering materials and compare the properties. Cambridge Engineering Selector (CES) EduPack is a regularly updated database which provides comprehensive information about the properties of almost 4,000 materials in the form of interactive, visual software.
