Reed How it’s built

What a catalytic converter actually does

Look down the inlet of a used can and the pipe does not keep going. A ceramic face is sitting in there — thousands of square cells, a pale brick stuffed in a rusty shell. Exhaust has to crawl through that maze. That is the catalytic converter. It is not the muffler.

Looking into a rusty catalytic converter, ceramic honeycomb brick filling the inlet
The RedBurn

The wash on those walls is the metal. Platinum, palladium, rhodium. Once the brick is hot, a three-way catalyst does three jobs on the same surface: it strips oxygen off NOx, and it burns leftover carbon monoxide and unburned fuel. Cold, the washcoat is just ceramic. Light-off is the whole point. A lot of cars put a first brick right off the manifold, where the gas still has the heat, and a second brick under the floor. Two bricks. One can, or two.

Used catalytic converter can on the ground, oval steel shell and cut pipes
Santeri Viinamäki

The muffler is a can too. Baffles and wool. It kills sound. It does not care what molecules leave. People hear a rasp and blame the cat. People smell rotten eggs and blame the muffler. The sulfur is the brick working a rich mix. A hollow rattle is the honeycomb broken loose in the shell.

Catalytic converter can in a Saab exhaust, flex joint ahead of the bulge under the floor
Ballista

On the stands, look forward of the resonator. Oval steel, a heat shield, a flex joint just ahead of the bulge. That is the chemistry can. The last can before the tip is the muffler.